E-cigarette personal vaporizer

ABSTRACT

A portable, personal storage and carrying case for an e-liquid e-cigarette PV in which the case includes: a refillable PV that is removable from the case; an electrical power source for re-charging a rechargeable battery in the PV; a user-replaceable reservoir for holding e-liquid; and an electrical or electronic pump adapted to transfer e-liquid from the reservoir to a chamber in the PV, the pump delivering a pre-defined or variable quantity of e-liquid from the reservoir; and in which the case is configured to automatically fully re-fill the PV with e-liquid and fully charge the PV so that the PV is in a fully re-filled and re-charged state when it is removed from the case.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of Ser. No. 15/069,083, filed Mar.14, 2016, which is a continuation of U.S. application Ser. No.14/633,863, filed Feb. 27, 2015, which is based on and claims priorityto UK Application No. 1403566.1, filed Feb. 28, 2014; UK Application No.1408173.1, filed May 8, 2014; UK Application No. 1413018.1, filed Jul.23, 2014; UK Application No. 1413021.5, filed Jul. 23, 2014; U.S.Provisional Application No. 62/045,651, filed Sep. 4, 2014; and U.S.Provisional Application No. 62/045,666, filed Sep. 4, 2014, the entirecontents of each of which being fully incorporated herein by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The field of the invention relates to an electronic cigarette personalvapouriser, also known as an electronic cigarette (e-cig ore-cigarette), vapestick, modding kit, personal vaporizer (PV), advancedpersonal vaporizer (APVs) or electronic nicotine delivery system (ENDS).In this specification, we will typically use ‘PV’ or ‘e-cigarette’ asthe generic term. A PV vapourises ‘e-liquid’ or vaping substance toproduce a non-pressurised vapour or mist for inhalation for pleasure orstress-relief, replicating or replacing the experience of smoking acigarette. An ‘E-liquid’ or vaping substance is a liquid (or gel orother state) from which vapour or mist for inhalation can be generatedand whose primary purpose is to deliver nicotine.

PVs are therefore mass-market consumer products that are equivalent tocigarettes, and are typically used by smokers as part of a cigarettereduction or cessation program. The main ingredients of e-liquids areusually a mix of propylene glycol and glycerine and a variableconcentration of tobacco-derived nicotine. E-liquids can include variousflavourings and also come with varying strengths of nicotine; users on anicotine reduction or cessation program can hence choose decreasingconcentrations of nicotine, including at the limit zero concentrationnicotine e-liquid. The term ‘e-liquid’ will be used in thisspecification as the generic term for any kind of vaping substance.

E-cigarette PVs were first conceived in 1963 and for the last 50 yearsof development have generally been seen as a separate and distinctcategory compared with conventional medicinal delivery systems. Toemphasise the difference over medicinal devices, we will also in thisspecification use the term ‘e-cigarette PV’, as opposed to the term‘PV’.

Despite this sector being over 50 years old, there are still manypractical problems that have not yet been solved and that are a barrierto e-cigarette PVs achieving mass-market success; they are still a longway from replacing conventional cigarettes. If they were to largelyreplace cigarettes, then some experts state that large-scale adoptioncould bring significant public health benefits. Writing in the BritishJournal of General Practice, DOI: 10.3399/bjgp14X681253, published 1September 2014, Prof Robert West and Dr Jamie Brown from UniversityCollege London stated that “For every million smokers who switched to ane-cigarette we could expect a reduction of more than 6000 prematuredeaths in the UK each year, even in the event that e-cigarette usecarries a significant risk of fatal diseases, and users were to continueto use them indefinitely.”

2. Technical Background

PVs are typically battery-powered devices which simulate tobacco smokingby producing inhalable vapour (typically propylene glycol and nicotine).They generally use a heating element known as an atomizer, thatvaporizes a liquid solution known as e-liquid or ‘juice’. E-liquidsusually contain a mixture of propylene glycol, vegetable glycerin,nicotine, and flavorings, while others release a flavored vapor withoutnicotine. Vaporization is an alternative to burning (smoking) thatavoids the inhalation of many irritating toxic and carcinogenicby-products. Apart from simulating tobacco smoking, the electronicvapouriser can also be used as a smoking-cessation aid or for nicotine(or other substance) dosage control.

Most electronic cigarettes take an overall cylindrical shape although awide array of shapes can be found: box, pipe styles etc. Firstgeneration electronic cigarettes were usually designed to simulatecigarettes in their use and appearance. They are often called‘cig-a-likes’. Cig-a-likes are usually disposable, low cost items andthe user-experience is often quite poor. New generation electroniccigarettes, often called mods, modding-kits or APV's (advanced personalvaporizer) have an increased nicotine-dispersal performance, housinghigher capacity batteries and come in various form factors, includingmetal tubes and boxes. Many electronic cigarettes are composed ofstandardized replaceable parts that are interchangeable from one brandto the other, while disposable devices combine all components into asingle part that is discarded when its liquid is depleted. Commoncomponents include a liquid delivery and container system like acartridge or a tank, an atomizer, and a power source.

Atomizer

An atomizer generally consist of a small heating element responsible forvaporizing e-liquid, as well as a wicking material that draws liquid in.Along with a battery, the atomizer is the central component of everypersonal vaporizer. Differences between atomizers cause differences inthe ingredients and their concentrations delivered to users, even whenthe same liquid is used.

A small length of resistance wire is coiled around the wicking materialand then connected to the positive and negative poles of the device.When activated the resistance wire (or coil) quickly heats up, thusturning the liquid into a vapor, which is then inhaled by the user.

Wicking materials vary greatly from one atomizer to another but silicafibers are the most commonly used in manufactured atomizers. A widearray of atomizers and e-liquid container combinations are available.

Cartomizers

A cartomizer (a portmanteau of cartridge and atomizer) or ‘carto’consists of an atomizer surrounded by a liquid-soaked poly-foam thatacts as an e-liquid holder. It is usually disposed of once the e-liquidacquires a burnt taste, which is usually due to an activation when thecoil is dry or when the cartomizer gets consistently flooded (gurgling)because of sedimentation of the wick. Most cartomizers are refillableeven if not advertised as such.

Cartomizers can be used on their own or in conjunction with a tank thatallows more e-liquid capacity. In this case the portmanteau word of“carto-tank” has been coined. When used in a tank, the cartomizer isinserted in a plastic, glass or metal tube and holes or slots have to bepunched on the sides of the cartomizer to allow liquid to reach thecoil.

Clearomizers

Clearomizers or “clearos”, not unlike cartotanks, use a clear tank inwhich an atomizer is inserted. Unlike cartotanks, however, no poly-foammaterial can be found in them. There are a lot of different wickingsystems employed inside of clearomizers to ensure good moistening of thewick without flooding the coil. Some rely on gravity to bring thee-liquid to the wick and coil assembly (bottom coil clearomizers forexample) whereas others rely on capillary action and to some degree theuser agitating the e-liquid while handling the clearomizer (top coilclearomizers)

Power

Most portable devices contain a rechargeable battery, which tends to bethe largest component of an electronic cigarette. The battery maycontain an electronic airflow sensor whereby activation is triggeredsimply by drawing breath through the device, while other models employ apower button that must be held during operation. An LED to indicateactivation may also be employed. Some manufacturers also offer acigarette pack-shaped portable charging and re-filling case (PCC), whichcontains a larger battery capable of charging e-cigarettes. Devicesaimed at more experienced users may sport additional features, such asvariable power output and support of a wide range of internal batteriesand atomizer configurations and tend to stray away from the cigaretteform factor. Some cheaper recent devices use an electret microphone witha custom IC to detect airflow and indicate battery status on theincluded blue LED.

Variable Power and Voltage Devices

Variable voltage or power personal vaporizers are devices that contain abuilt in electronic chip that allows the user to adjust the power thatgoes through the heating element. They usually incorporate a LED screento display various information. Variable PV's eliminate the need ofhaving to replace an atomizer with another one of lower or higherelectrical resistance to change the intensity of the vapour (the lowerthe resistance, the higher the vapour intensity). They also featurevoltage regulation and some battery protection.

Some of these devices offer additional features through their menusystem such as: atomizer resistance checker, remaining battery voltage,puff counter, activation cut-off etc.

E-liquid

E-liquid, e-juice or simply “juice”, refers to a liquid solution thatproduces a mist or vapour when heated by an atomizer. The mainingredients of e-liquids are usually a mix of propylene glycol (PG),vegetable glycerin (VG), and/or polyethylene glycol 400 (PEG400),sometimes with differing levels of alcohol mixed with concentrated orextracted flavorings; and a variable concentration of tobacco-derivednicotine. There is variability in the purity, kinds and concentrationsof chemicals used in liquids, and significant variability betweenlabeled content and concentration and actual content and concentration

E-liquid is often sold in bottles or pre-filled disposable cartridges,or as a kit for consumers to make their own. Components are alsoavailable individually and consumers may choose to modify or boost theirflavor, nicotine strength, or concentration with various offerings.Pre-made e-liquids are manufactured with various tobacco, fruit, andother flavors, as well as variable nicotine concentrations (includingnicotine-free versions). The standard notation “mg/ml” is often used inlabeling for denoting nicotine concentration, and is sometimes shortenedto a simple “mg”.

Source acknowledgement for this Technical Background section: Wikipediaentry on e-cigarettes.

3. Discussion of Related Art

The patent literature in this field is quite extensive, with theearliest e-cigarette PV dating from 1963.

Some of the more relevant patent disclosures in this space include thefollowing. We highlight some of the main reasons why each item of priorart lacks relevance.

US 2014/020697 Liu.

-   -   Just a PV charging device    -   No e-liquid re-filling capability    -   No user-replaceable e-liquid cartridge    -   No data processor with communications capability

CN 202679020 Chen:

-   -   Just a PV charging device    -   No e-liquid re-filling capability    -   No user-replaceable e-liquid cartridge    -   No data processor with communications capability

US 2013/342157 Liu

-   -   Just a PV charging device    -   No e-liquid re-filling capability    -   No user-replaceable e-liquid cartridge    -   No data processor with communications capability

CN 201630238 Jian

-   -   Just a PV charging device    -   No e-liquid re-filling capability    -   No user-replaceable e-liquid cartridge    -   No data processor with communications capability

WO 2011/095781 Kind

-   -   Not e-liquid, e-cigarette related    -   No e-liquid re-filling capability—fills a pressurised gas        instead    -   No user-replaceable e-liquid cartridge (the gas canister is not        described as being user-replaceable and doing so would in fact        require the user to take the entire unit to pieces, so it        teaches away from user-replaceability)    -   No electrical charging capability (device has no battery)    -   No data processor with communications capability

US 2012/167906 Gysland

-   -   Not a PV charging device    -   Just an e-liquid filling device, using a standard e-liquid        squeezable bottle; the user unscrews the PV, separating it into        an atomiser portion and an e-liquid chamber portion, and then        screws the e-liquid chamber portion into one end of this device        and screws the squeezable bottle into the other end of this        device and then squeezes the bottle to transfer the e-liquid        over.    -   No charging capability    -   No data processor with communications capability

WO 2011/026846 Wedegree

-   -   Not e-liquid PV related—instead, it's a propane powered        heat-based device    -   No e-liquid re-filling, just re-fills a device with liquid        propane    -   Mouthpiece is removed before the device is inserted for gas        re-filling    -   No charging capability    -   No user-replaceable cartridge    -   No data processor with communications capability

WO 2009/001078 Kind

-   -   Not e-liquid, e-cigarette related    -   No e-liquid re-filling—fills pressurised gas instead    -   No user-replaceable cartridge (gas canister in the refill unit        is itself re-filled)    -   No charging capability    -   No data processor with communications capability

For completeness, we mention also another item of non-analogous art,which is firmly in the medical inhalation field and lacks any specificreference to e-cigarettes or nicotine delivery. The field of thisinvention is rather different from medical inhalation devices, such asasthma inhalers or other metered dose inhalers, since cigarette smokingis very clearly not a medicinal activity. Specifically, the mind-set ofthe e-cigarette designer is to replicate as closely as possible thenon-medicinal cigarette smoking experience, but without combustingtobacco. Metered dose inhalers on the other hand are typically designedfor accurate, rapid, and very occasional (e.g. emergency-only) oraldelivery of one or two doses of pressurised medicinal aerosol; the userexperience of a PV is quite different, with relatively slow, butfrequently repeated inhalations of a mist or vapour from anon-pressurised source; the experience is designed to be similar to, andhence an effective replacement for, the experience of smoking aconventional tobacco cigarette. One example of a metered dose inhaler isshown in U.S. Pat. No. 6,637,430 Ponwell. This lacks relevance for thefollowing reasons:

-   -   No explicit relevance to e-cigarettes—primarily, this is a        piezo-electric metered dose inhaler system for respiratory        medicines—a very different field from e-cigarette PVs    -   Not suitable for re-filling PVs since it uses a needle in the        case to puncture a rubber septum in the metered dose inhaler (a        conventional approach used in the medicinal context where        maintaining sterility of the medicament is key). But this rubber        septum would degrade and tear with more than a few        re-insertions; this is not an issue for a metered dose inhaler        which is used relatively infrequently and sterility of the        medicament is more important than durability of the medicament        transfer mechanism.    -   No user-replaceable liquid cartridge (in fact, teaches        re-filling the medicament container, so it is not a        user-replaceable cartridge)    -   Is not a combined carrying and storage case for the metered dose        inhaler

Emphasising the distance between the field of metered dose inhalers ande-cigarette PV design, one of the many problems facing the designer ofan e-cigarette PV is how to minimise any toxins in the vapour producedby the PV.

For example, in the paper in the New England Journal of Medicine,‘Hidden Formaldehyde in E-Cigarette Aerosols’ N Engl J Med 2015;372:392-394, the authors describe how they tested for the presence offormaldehyde-releasing agents (whose safety when inhaled is not fullyunderstood) in the vapour of an e-cigarette PV with a variable voltagepower source: ‘At low voltage (3.3 V), we did not detect the formationof any formaldehyde-releasing agents (estimated limit of detection,approximately 0.1 μg per 10 puffs). At high voltage (5.0 V), a mean(±SE) of 380±90 μg per sample (10 puffs) of formaldehyde was detected asformaldehyde-releasing agents.’ They go on to state ‘Howformaldehyde-releasing agents behave in the respiratory tract isunknown, but formaldehyde is an International Agency for Research onCancer group 1 carcinogen.’ One solution would appear to be to ensurethat e-cigarette PVs run at low voltage (e.g. 3.3V) and not highervoltages, like 5V. But the problem that then arises is that the PVcurrent has to be higher for a good ‘vaping’ experience, and that inturn means that (a) the PV battery runs down more quickly, and (b) thee-liquid is consumed more rapidly.

This is inconvenient with conventional designs of PV because rechargingor replacing a battery takes time and because re-filling with e-liquidtakes time; users would for example then need to carry around sparebatteries or charging cables and e-liquid bottles. This is verydifferent from the relatively straightforward and simple experience(and, to smokers, deeply attractive ritual) of opening a pack ofconventional cigarettes and just lighting up. Because we see replicatingthe behavioural aspects of the cigarette smoking user experience as keyto a successful product, these are major drawbacks for conventional PVdesigns.

One solution is to use a large ‘modding-kit’ type PV with a very largecapacity battery that can run at the low 3.3V voltage associated with noformaldehyde release and a large e-liquid reservoir. These devices canbe the size of several packets of cigarettes, and so the user sacrificeseasy portability. But the performance or user experience can be good,since these devices can produce good quantities of vapour, without theneed for frequent and inconvenient battery re-charging or replacementand e-liquid re filling. When e-liquid does need to be replenishedhowever, that is typically done by dis-assembling the unit to expose thereservoir and to then squeeze e-liquid into the reservoir from a smallbottle; this can be slow and cumbersome; users often then carry around areplacement bottle or e-liquid, especially if they are usinge-cigarettes to quit tobacco smoking, since if they were to run out ofe-liquid, then the temptation to buy a packet of cigarettes to smokecould prove hard to resist. And this complex e-liquid re-filling processclearly has none of the simplicity or attractive ritual of opening apacket of cigarettes and lighting up.

An ideal solution would be an e-cigarette PV with the form factor of aconventional cigarette, and with the best aspects of the performance anduser experience of a large modding kit type PV. This specificationdescribes such a solution. The solution is designed to replicate many ofthe key behavioural and experiential aspects that make smokingattractive to smokers (e.g. the tactile satisfaction of holding acigarette packet and opening the lid and withdrawing a cigarette; theaction of holding a slim cigarette; the simplicity of the user's onlyaction being to light up). Replicating these user experience aspects iswe believe key to the successful mass-market adoption of e-cigarettesand hence delivering on their considerable public health potential.

SUMMARY OF THE INVENTION

The invention is a portable, personal storage and carrying case for ane-liquid e-cigarette PV which is operable to re-fill the PV withe-liquid if the PV is inserted, fully or in part, into the case, whilstmaintaining the PV whole and intact. An embodiment comprises a portable,personal storage and carrying case for an e-liquid e-cigarette PV inwhich the case includes: a refillable PV that is removable from thecase; an electrical power source for re-charging a rechargeable batteryin the PV; a user-replaceable reservoir for holding e-liquid; and anelectrical or electronic pump adapted to transfer e-liquid from thereservoir to a chamber in the PV, the pump delivering a pre-defined orvariable quantity of e-liquid from the reservoir; and in which the caseis configured to automatically fully re-fill the PV with e-liquid andfully charge the PV so that the PV is in a fully re-filled andre-charged state when it is removed from the case.

BRIEF DESCRIPTION OF THE FIGURES

Examples of the invention will now be described with reference to theaccompanying diagrams, in which:

FIG. 1 is a schematic view of a prior art e-cigarette, showing how thedevice can be dis-assembled into three pieces.

All of the remaining figures depict elements of an e-cigarette PV or PVcase that solve problems with the prior art.

FIG. 2 is an isometric view of an e-cigarette PV;

FIGS. 3 and 4 show that e-cigarette partly withdrawn from its portable,personal storage and carrying case;

FIG. 5 shows a user-replaceable e-liquid cartridge adapted to beinserted into or attached to a portable, personal storage and carryingcase for a PV;

FIG. 6A is view of a simplified version of the case showing the userreplaceable e-liquid cartridge and the battery withdrawn from theportable re-filling and re-charging and re-filling case and FIG. 6B sowsthe case with the PV holder hinged downwards, ready to accept a PV;

FIG. 7 is a cross sectional view of the portable case of FIG. 6,together with an e-cigarette PV;

FIG. 8 shows the PV being inserted into the portable case of FIG. 6 forre-filling with e-liquid;

FIG. 9 is a detailed view of the e-liquid-filling mechanism in theportable case of FIG. 6;

FIG. 10 is a cross sectional view of the PV when stored in the portablecase of FIG. 6;

FIG. 11 is a cross-sectional view of the PV of FIG. 6;

FIG. 12 is an example of a portable case with side-loading of the PV;

FIG. 13 is an example of a portable case with top-loading of the PV;

FIG. 14 is a cross-sectional view of the PV as it re-fills with e-liquidwhen pushed down onto the re-fill mechanism;

FIG. 15 shows an isometric view of a working prototype of the case, withthe PV holder or chassis shown closed;

FIG. 16 shows an isometric view of the working prototype of the case,with the PV holder or chassis shown opened, and the PV fully insertedinto the holder;

FIG. 17 shows an isometric view of the working prototype of the case,with the PV holder or chassis shown opened, and the PV raised upwards,ready for withdrawal by the user;

FIG. 18 are isometric views of the holder or chassis;

FIG. 19 is an isometric view of the PV used in the working prototype;

FIG. 20 is a cross-section view of the PV;

FIG. 21 is a cross-section view of the case, with chassis closed and noPV present;

FIG. 22 is a cross-section view of the case, with chassis open and no PVpresent; FIG. 23 is a cross-section view of the case, with chassisclosed and PV present; the inter-lock is not engaged with the slidingcontact block;

FIG. 24 is a cross-section view of the case, with chassis closed and PVpresent; the inter-lock is engaged with the sliding contact block;

FIG. 25 is a cross-section view of the case, with chassis open and PVpresent; the inter-lock is engaged with the sliding contact block andthe PV is being heated;

FIG. 26 is a cross-section view of the case, with chassis open and PVpresent; the inter-lock is no longer engaged with the sliding contactblock and the PV is shown popped up from the chassis, ready for the userto extract;

FIGS. 27-30 is a close up of the sliding contact block assembly and PVin each of the four FIGS. 23-26;

FIG. 31 is an exploded view of the sliding contact block assembly;

FIG. 32A is a side view of the sliding contact block assembly;

FIG. 32B is a top view of the sliding contact block assembly;

FIG. 33 is an exploded view of the key components, including PV,chassis, cartridge, and the sides of the case;

FIG. 34 is a close up showing the PV resting against the pump in thecase; chassis is open;

FIG. 35 is a close up showing the PV pushed down against the pump;chassis is open;

FIG. 36 is a close up showing the PV pushed down against the pump;chassis is closed;

FIGS. 37-40 show the pump at its various positions;

FIGS. 41-45 shows the user-replaceable e-liquid cartridge, withintegrated pump and overflow valve, in its various positions;

FIG. 46 is an exploded isometric view of the PV;

FIG. 47 is an isometric view of the PV;

FIG. 48 is a close-up view of the wick and coil assembly; the coil runsperpendicular across the long axis of the PV;

FIG. 49 is a close-up view of a different design of wick and coilassembly; the coil runs parallel to the long axis of the PV;

FIG. 50 is an exploded view of the ring connector that provides powerand data contacts on the PV

FIG. 51 is a cross-sectional view of the ring connector;

FIG. 52-54 show the variable air intakes of the PV;

FIG. 55 is a high-level schematic showing a portable re-filling caseable to communicate wirelessly and also through a wired connection to asmartphone, a laptop and a modem;

FIG. 56 shows schematically that the portable re-filling unit includeselectronics componentry, such as a memory, wireless/wired connectivity,software, and a controller/processor; there are four e-liquidcartridges, each with a different flavor and/or strength of nicotine.

FIG. 57 shows how the user's smartphone can display the current levelsof e-liquid in each separate cartridge;

FIG. 58 shows a PV being withdrawn from its case; this automaticallyinitiates heating of the e-liquid using the battery in the PV. A ‘ready’light on the PV illuminates when the device is ready to use.

FIG. 59 shows an example of a PV including an indication of how muchsubstance has been vapourised;

FIG. 60 shows a conventional two-part PV, with an e-liquid cartridgeabove the atomizer and the atomiser above the battery, plus a thirdmodule in the middle that indicates the amount of e-liquid consumed;

FIG. 61 shows a time-locked case for a PV;

FIG. 62 shows a humidity sensor for a PV;

FIGS. 63-67 show various approaches to eliminating or reducing leakageof e-liquid from the PV;

FIG. 68 shows a PV with a hygienic mouthpiece;

FIG. 69 shows a PV with a hygienic mouthpiece and that uses asingle-dose e-liquid capsule at the end of the PV furthest from themouthpiece;

FIG. 70 shows a PV and a dispenser for single-dose e-liquid capsules;

FIGS. 71-76 show cross-sectional views of a PV with various atomizationimprovements;

KEY TO NUMERALS IN THE FIGURES

1 Personal Vaporiser—PV

2 PV holder and receptacle chassis

3 Reservoir (a user-replaceable e-liquid cartridge)

4 Pump

5 4 Way Sliding Contact Block

6 Case—L/h

7 Case—R/h

8 Cam Block

9 Guide Plate

10 Pawl/Lever

11 Solenoid Mounting Block

12 Chassis Lid

13 Valve Mounting Cup

14 Valve Mounting Cap

15 Reservoir Gasket

16 PCB—Main Case

17 Leaf Spring

18 Pivot Screw

19 Spring—Pawl/Lever

20 Split Spring Pin—Pawl Spring

21 Split Spring Pin—Pawl Pivot

22 Solenoid

23 Spring—4 Way Sliding Contact Block

24 Contact Finger

25 Ring Contact

26 Insulating Ring

27 Seal Inlet—PV

28 O Ring—PV Chamber

29 Valve—PV Tip

30 Spring—PV Tip Valve

31 Grub Screw—PV Tip

32 PV Tip

33 Screw—Guide Plate

34 Valve—Pump

35 Screw—Leaf Spring

36 End Cap—Ring Connector

37 PCB Mounting Cap/Ring Connector

38 Pin—180°—Ring Connector

39 Pin—135°—Ring Connector

40 Pin—45°—Ring Connector

41 Pin—0°—Ring Connector

42 Ring Contact

43 Insulation Ring

44 Screw—Ring Connector

45 Support Ring—4 Way Sliding Connector

46 Body—4 Way Sliding Connector

47 Wires—4 Way Connector Block

48 Fluid Chamber—PV

49 Ring Connector Assembly

50 Vaporiser End Cap

51 Vaporiser Insulating Sleeve

52 Coil and Wick Assembly

53 Vaporiser Outer Body

54 Bush—Vaporiser Body

55 Vaporiser Inner Body

56 Tube Body—Vaporiser

57 Pressure Sensor Housing

58 Pressure Sensor/Transducer

59 Battery—PV

60 PV PCB

61 Hollow Stem Shaft

62 Moulded Rim/Undercut

63 Moulded Lip Seal

64 RGB LED Indicator

65 Reset Switch

66 Arduino Chip

67 Micro USB Connector

68 Battery—Chassis

69 PCB Standoffs

70 Microswitch

71 Power Connection Insulating Bush

80 Fluid chamber inside the pump

81 Fluid inlet end

82 Fluid outlet end

83 Slotted tube for ball

84 Feed-through hole

85 Piston

86 Piston rod

87 Bias spring

88 Valve stem

89 Piston return spring

90 Valve cap

91 Tapered valve seat

92 Ball valve

93 Return spring

94 Valve seal washer

95 Reservoir cap

96 Spring guide

97 Reservoir body

98 longitudinal heating coil

99 heating coil chassis

100 Re-filling and re-charging case

DETAILED DESCRIPTION

FIG. 1 shows a conventional personal vapouriser (‘PV’). The PV includesthe following key components: a ‘juice’ or ‘e-liquid’ delivery andcontainer system, called a cartridge (A), and an atomizer (B) forvapourising the juice, and a power source (C) to power the atomiser. Thecartridge also forms the mouthpiece. A typical design, as shown in FIG.1, requires the battery (C) to be screwed into the atomiser (B), and thecartridge (A) is then pushed onto the free end of the atomiser B. Whenthe cartridge is fully consumed, the user discards the used cartridgeand replaces it with a new one. An alternative design sees the cartridgeas user-refillable, typically from a small bottle of e-liquid.

Conventional PV designs suffer a number of drawbacks. This DetailedDescription section describes a number of high-level features whichaddress the most significant drawbacks. An implementation of thisinvention uses one or more of these high level features.

We will organise our description of the features using the followingcategories:

Section A. E-Liquid Re-filling and Re-Charging Storing and Carrying Case

Feature 1. Combined re-charge and re-fill storage and carrying case

Feature 2. Case with movable PV holder

Feature 3. Re-Filling the PV

Feature 4. PV Locking mechanism

Feature 5. Data connectivity

Feature 6. E-fulfilment

Section B. PV: Simplicity and Ease of Use

Feature 7. Re-fillable and re-chargeable PV

Feature 8. PV with pre-heat

Feature 9. PV with dosage indication

Feature 10. PV with drip prevention

Section C. User-replaceable e-liquid cartridge

Feature 11. User-replaceable e-liquid cartridge that fits into theportable storage and carrying case

Section D Miscellaneous

Feature 12 Hygienic PV

Feature 13 Single capsule dispenser

Feature 14 Single capsule PV

Feature 15 Various constructional improvements

Note that each high-level feature listed above, and the related,detailed features listed below for each high-level feature, can becombined with any other high-level feature and any other detailedfeature. Appendix 1 provides a consolidated summary of each of these.

Introduction

The following sections will describe an e-cigarette system thatimplements aspects of the invention; this system includes:

-   -   an e-cigarette PV; the size and shape can be similar to, or        slightly larger than, a conventional cigarette. This is shown in        FIG. 2. Mimicking the size and shape of a conventional cigarette        is very helpful since it makes the PV much more attractive to        smokers trying to quit cigarettes.    -   a portable, personal storage and carrying case that both        re-charges the battery in the PV and also re-fills the e-liquid        chamber in the PV; the size and shape can be similar to, or        slightly larger than, a conventional cigarette packet of 20        cigarettes. This is shown in FIG. 3 (PV partly withdrawn from        its case) and FIG. 4 (PV fully withdrawn from its case)    -   a user-replaceable cartridge that is slotted into the case and        can be readily swapped out by the user for a fresh cartridge        when running low or to try different strengths or flavours of        e-liquid. The cartridge capacity can be approximately 10 ml of        e-liquid; this might approximate very roughly to five packets of        20 cigarettes. See FIG. 5.

Because the PV can be stored in the case whenever it is not being used,and the case may operate to re-fill the PV from its user-replaceablecartridge and also re-charge the PV, the PV can always be in its fullyre-filled and re-charged state whenever it is removed from the case.There is no longer any need for the user to carry around spare batteriesfor the PV or small re-fill bottles of e-liquid.

One design of this new system, as shown in FIGS. 3 and 4, has the PVbeing automatically replenished with e-liquid when it is slotted into aholder that hinges outwards from the main body of the case and the usermanually pushes the PV up and down, activating a micro-pump thattransfers e-liquid from the user-replaceable cartridge in the case to areservoir in the PV. When the holder is closed into the case, theelectrical contacts on the PV engage with charging contacts inside thecase, transferring power from the case battery to the rechargeablebattery in the PV. This means:

-   -   Vaping performance of the PV is always optimal; there is none of        the performance degradation associated with a weak PV battery or        a nearly empty PV e-liquid reservoir.    -   The PV can vape at the lower voltages (possibly associated with        zero formaldehyde emissions—see Discussion of Related Art        above): in a conventional system this can provide a good vaping        experience when the resistance of the heating wire in the        atomizer is sufficiently low (and hence the overall power is        sufficient but not too high, typically in the 6-8 watts band),        but leads to the serious disadvantages of high battery drain and        high e-liquid consumption. These disadvantages are now rendered        wholly irrelevant with the new system because of the ease of        both re-filling and re-charging the PV using the storage and        carrying case.    -   Because the storage case is designed to be a portable, personal        storage and carrying case (typically similar in size to a pack        of 20 cigarettes), the user will generally always carry it with        him or her (in their pocket or handbag etc) and hence always        store the PV away in it. Because the storage case is        considerably larger than a conventional PV, it can store far        more e-liquid in its user-replaceable e-liquid cartridge and can        include a much larger capacity battery. Hence, the e-liquid        cartridge in the carrying case only needs to be replaced        relatively infrequently (for a typical 20 cigarette a day smoker        switching to this system, then a new cartridge might be needed        every five days: very roughly, 10 inhalations consumes 0.1 ml of        e-liquid or the equivalent of one cigarette; the PV itself        stores typically 2 ml of e-liquid, or the equivalent of twenty        cigarettes; and the cartridge in the case typically stores        approximately 10 ml of e-liquid for compliance with EU Directive        2014/40/EU (known as the Tobacco Products Directive) or the        equivalent of five packets of twenty cigarettes. Further, the        case only needs to be re-charged (e.g. using a USB charging        cable connected to a laptop or mains power adaptor) infrequently        as well (perhaps once a week, depending on use).

This system is designed to re-fill and re-charge a PV many thousands oftimes without damaging either case or PV. This system gives the user ane-cigarette PV with the form factor of a conventional cigarette, andwith the performance and user experience (e.g. vapour intensity) of alarge modding kit-type PV, but with none of the inconvenience ofdis-assembling the PV to re-fill the PV with e-liquid from a smallbottle. This system also replicates the rituals of handling an objectsimilar in size to a packet of twenty cigarettes, of opening that packetand withdrawing a cigarette; and the tactile familiarity of holding acigarette sized object and inhaling from it. This combination is webelieve key to the large-scale consumer adoption of e-cigarettes.

Section A. E-Liquid Re-filling and Re-Charging Storage and Carrying Case

In this Section A, we will describe the e-liquid re-filling andre-charging storage and carrying case. The case implements a number ofuseful features:

Feature 1. Combined re-charge and re-fill storage and carrying case

Feature 2. Case with movable PV holder

Feature 3. Re-Filling the PV

Feature 4. PV Locking mechanism

Feature 5. Data connectivity

Feature 6. E-fulfilment

In this Section A, we will summarise each of these six features in turn,and then describe them in detail. Appendix 1 collects these featuresinto a consolidated summary.

Feature 1. Combined Re-Charge and Re-Fill Storage and Carrying Case

The feature is: A portable, personal storage and carrying case for ane-liquid e-cigarette PV in which the case includes: (a) a power sourcefor re-charging a rechargeable battery in the PV; (b) a reservoir forholding e-liquid; and (c) a fluid transfer system adapted to transfere-liquid from the reservoir to a chamber in the PV. The reservoir forholding e-liquid is, in one implementation, a user-replaceable e-liquidcartridge.

As noted above, this approach is key to an e-cigarette PV with the formfactor of a conventional cigarette, and with the performance and userexperience of a large modding kit-type PV: re-filling and re-charging ofthe PV is fast and convenient, since it can occur readily and easilywhenever the user returns the PV to its case. The e-liquid cartridge inthe case requires relatively infrequent (e.g. weekly) but fast, andmess-free replacement; it is far easier than re-filling manually bysqueezing e-liquid from a small bottle. It may also have a simplerelationship with conventional cigarette consumption (e.g. ‘one hundredcigarettes in a case’).

Note also that the two features of re-charging the PV's battery andre-filling the PV's e-liquid chamber have a working interrelation thatproduces an overall improved result—we have a synergistic combination offeatures, entirely lacking for example in the non-analagous field ofmetered dose inhalers, exemplified by U.S. Pat. No. 6,637,430 Ponwell.

Specifically, an effective e-liquid PV consumes a significant amount ofe-liquid and also current. Cigalites have not sold well in the marketbecause they permit neither high e-liquid consumption nor high current.Cases that can merely re-charge a PV are not good enough because the PVsneed to be frequently re-filled with e-liquid, which meansdis-assembling them, which is messy and inconvenient. But if you add ane-liquid re-filling feature to the case, as envisaged in this Feature 1,then that means you can run the heating element in the PV at asufficiently high current to give much better performance—the fact thatyou are also now consuming more e-liquid since you are heating it fasterand also now depleting the PV battery faster does not matter anymorebecause you can both conveniently re-fill the PV with e-liquid when youinsert the PV back into the carrying case and also re-charge the PVbattery. So adding an e-liquid PV re-fill capability has a workinginterrelationship with the PV battery re-charging function—it enablesthe PV to run at higher current and also higher juice consumption rates,giving much better vaping performance, but without the inconvenience ofhaving to regularly dis-assemble the PV for re-filling or batterychange.

Also, with this Feature 1, we can run the atomiser at the lower voltages(e.g. 3.3V) that likely produce no formaldehyde if we use low resistancewire in the atomiser—this not only produces no formaldehyde but willalso produce warmer vapour and more vapour than would be made if thedevice were running at 5V.

Systems that do not have a combined re-fill and re-charge carry casecannot replicate this experience at lower voltages like 3.3V, because a3.3V and low resistance wire combination means faster battery drain andfaster e-liquid consumption than a higher voltage and higher resistancewire combination. As noted above, faster PV battery drain and fastere-liquid consumption are not disadvantages with the present Feature 1because re-charging the PV and re-filling it with e-Liquid is fast andconvenient and can happen readily whenever the PV is returned to thestorage and carrying case.

Feature 2. Case with Movable PV Holder

The feature is: A portable, personal storage and carrying case for ane-liquid e-cigarette PV in which moving a movable holder or chassis,into which the PV has been inserted, brings electrical charging contactson the PV into direct or indirect engagement with electrical chargingcontacts in the case that are connected to a power source, such as arechargeable battery in the case.

By requiring the PV to be inserted into a movable holder or chassis inthe case, it becomes much easier to guide the PV into accurate alignmentwith the electrical charging contacts in the case, as well as(preferably) guide an e-liquid filling aperture in the PV into accuratealignment with an e-liquid nozzle used to transfer e-liquid into the PV.Accurate alignment is highly desirable to ensure good electricalcontact, to minimise leakage and to ensure optimum performance of thee-liquid fluid transfer mechanism.

Feature 3. Re-Filling the PV

The feature is: A portable, personal storage and carrying case for ane-liquid e-cigarette PV which re-fills the PV with e-liquid if the PV isinserted, fully or in part, into the case, whilst maintaining the PVwhole and intact.

By ensuring that the PV remains entirely intact (in contrast for exampleto some medicinal inhalation devices which require a needle in thecanister that stores medication fluids to puncture a rubber septum inthe inhalation device), the design is robust and can be used forthousands of re-filling operations (as opposed to a very small numberwith a needle that punctures a rubber septum).

Another related high-level feature is: A portable, personal storage andcarrying case for an e-liquid e-cigarette PV which re-fills the PV usinga fluid transfer system, such as a pump activated by depressing andreleasing the entire, complete PV, whilst the PV is held in a holder ofthe case in accurate alignment with the fluid transfer mechanism.

Using a holder to hold the PV in accurate alignment with a fluidtransfer system is highly desirable to minimise leakage and to ensureoptimum performance of the e-liquid fluid transfer mechanism,particularly where that mechanism is a pump activated by relative motionof the PV against the pump, since if the PV is not aligned correctly(e.g. along the longitudinal axis of the pump nozzle), the pump may notoperate efficiently and there may be leakage.

A related high-level feature is: An e-liquid e-cigarette PV adapted tobe re-filled with e-liquid when inserted into a case, in which the PVincludes an e-liquid filling aperture positioned centrally along themain axis of the PV to minimise any off-centre forces that couldotherwise compromise e-liquid sealing.

Another high-level feature is: A portable, personal storage and carryingcase for an e-liquid e-cigarette PV in which the case is adapted totransfer e-liquid to an e-cigarette PV from a user-replaceable e-liquidcartridge in the case.

If the case includes a user-replaceable cartridge, then it becomes fastand mess-free for the user to replace user cartridges and try newflavours or strengths of e-liquid by swapping our the cartridge. Sincethe cartridge capacity will be much greater than the PV's e-liquidchamber (for example, 10 ml for the user-replaceable cartridge ascompared to 1 or 2 ml in the PV chamber), replacement of the cartridgehappens relatively infrequently—typically once every 5 days for a userreplicating smoking 20 cigarettes a day. That also gives the user aneasy to grasp measure of the effectiveness of any nicotine reductionprogram they are following—moving progressively from replacing acartridge from every 5 days, to every 6 days, to every 7 days etc. Formany ordinary users, this is an easy metric to follow.

Feature 4. PV Locking Mechanism

The feature is: A portable, personal storage and carrying case for ane-liquid e-cigarette PV which is adapted to lock the PV securely in acharging position; and when the PV is locked in the charging position,then electrical charging contacts on the PV are in direct or indirectengagement with electrical charging contacts in the case that areconnected to a power source, such as a rechargeable battery, in thecase.

By ensuring that the PV is locked in position, effective charging canoccur and also the risk of damaging the electrical contacts (on both PVand in the case) by inadvertent movement of the PV is reduced. That isespecially important since the case is a portable storage and carryingcase.

Feature 5. Case with Data Connectivity

The feature is: A portable, personal storage and carrying case for ane-liquid e-cigarette PV in which the case includes (a) user-replaceablee-liquid cartridge; and (b) a fluid transfer system adapted to transfere-liquid from the cartridge to a chamber in the PV; in which the caseincludes a data processor that controls sending a signal requesting areplacement for the user-replaceable e-liquid cartridge in the case.

Enabling the case to send a request for a replacement e-liquid cartridgeis very convenient for the user and also ensures that replacementcartridges are supplied in a timely manner—this is especially importantwhen the user is on a tobacco or nicotine reduction programme since ifthe case runs out of e-liquid, then the user may well be tempted back tousing cigarettes. So the efficacy of adopting this system as a cigarettereplacement (and health concerns with cigarettes is overwhelmingly thereason given for e-cigarette adoption) benefits greatly from the timely,automatic, background ordering and supply direct to the end-user ofreplacement cartridges.

Feature 6. E-fulfilment Method

The high-level feature is: Method used in portable, personal storage andcarrying case adapted specifically for a refillable e-cigarette PV andthat re-fills and re-charges the PV, the method including the steps ofthe case (a) transferring e-liquid from a user-replaceable e-liquidcartridge to the PV and (b) automatically sending a signal requesting areplacement for the user-replaceable e-liquid cartridge to ane-fulfilment platform, either directly or via a connected smartphone.The method may include the steps of the case (a) detecting the level ofor quantity of e-liquid in a user-replaceable e-liquid cartridge in thecase and (b) automatically sending a signal requesting a replacement forthe user-replaceable e-liquid cartridge to an e-fulfilment platform,either directly or via a connected smartphone.

This feature is the method that is associated with Feature 5 and thesame advantages apply. Note that ‘detecting the level of or quantity ofe-liquid in a user-replaceable e-liquid cartridge in the case’ could bedirect, or could be indirect, such as inferred from the number ofre-fills of the PV that have been completed with that cartridge, or thetotal number of inhalations made with that cartridge.

Further optional features (each of which can be combined with any of theothers high-level features 1-6 above) include the following:

-   -   the movable chassis also has mounted on it an e-fluid reservoir,        a battery, a printed circuit board and a fluid transfer        mechanism    -   a metered dose or quantity of the e-liquid is delivered by the        fluid transfer mechanism in the case to the PV—typically 0.1 ml        per individual pumping action where a micro-pump is used.    -   the portable re-filling case or unit comprises a holder for        housing, securing or engaging with the personal vapouriser.    -   the holder comprises a biasing means for receiving the personal        vapouriser in a support position, the biasing means being        arranged such that a user depressing the personal vapouriser        causes the biasing means to allow the personal vapouriser to        engage with the refill mechanism, in a refill position.    -   the holder can be rotatably connected to the portable re-filling        unit such that it can move between an open and closed        configuration, the open and closed configurations having        corresponding personal vapouriser positions, wherein in the        closed configuration the personal vapouriser engages with the        refill mechanism to receive a dose of substance and in the open        configuration the personal vapouriser is disengaged from the        refill mechanism.    -   the refill mechanism comprises a pump.    -   the refill mechanism comprises a refill valve.    -   the refill mechanism is electronically controlled.    -   the portable re-filling case further comprises a        counter/measuring system for counting or estimating substance        consumption-related data, such as the number of times a personal        vapouriser has been refilled from the fluid reservoir.    -   The counter/measuring system counts the number of times the        personal vapouriser has been inserted into the unit for        re-filling.    -   the counter/measuring system is resettable and the portable        re-filling unit stores and/or displays a value provided by the        counter/measuring system which corresponds to the number of        times the personal vapouriser has been refilled from the fluid        reservoir.    -   The counter/measuring system directly measures        consumption-related data by measuring the change in the amount        of substance stored in the unit.    -   the portable re-filling case or unit stores the        consumption-related data and transmits that data to another        device, such as a smartphone, using a wireless or non-wireless        connection.    -   the fluid reservoir is a liquid cartridge which is removable        from the portable re-filling unit such that it can be replaced.    -   The portable re-filling case or unit is further adapted to        modify the amount of vapour fluid in a delivered dose of vapour        fluid.

In the next section of Section A, we will detail the operation of thefollowing features:

Feature 1: Combined re-charge and re-fill storage and carrying case

Feature 2: Case with movable PV holder

Feature 3: Re-Filling the PV

Feature 4: PV Locking mechanism

Features 1, 2, 3 and 4. Combined re-charge and re-fill storage andcarrying case;

-   -   Case with movable PV holder;    -   Re-Filling the PV;    -   PV Locking mechanism

The following section describes the case and the PV in more detail,focusing on these four features. The relevant Figures are FIGS. 6-10.

A portable charging device for replenishing the e-liquid or vapour fluidof an e-cigarette PV comprises: an e-liquid reservoir for storingmultiple dosages of e-liquid; and a refill mechanism configured toengage with the e-cigarette PV to deliver a dose of e-liquid from thereservoir to the e-cigarette PV.

Embodiments may provide a re-filling case for refuelling the e-cigarettePV with single dose (or predetermined by end user) multiple doses ofe-liquid. The e-liquid may be supplied to the e-cigarette PV from a tankin the charging and re-filling case holding a larger reserve ofe-liquid. The tank may be a user-replaceable cartridge.

A single dose of e-liquid delivered to the PV (and subsequently held inthe e-liquid chamber within the PV) may be equivalent to a singlemeasure of substance (such as the quantum of nicotine inhaled in oneordinary cigarette). Typically, 0.1 ml is delivered using the micro-pumpdesign described later in this section with each pumping action; this isequivalent to approximately ten puffs of a cigarette. The e-liquidchamber in the PV typically holds between 1 ml and 3 ml of e-liquid,very roughly equivalent to between ten and thirty cigarettes.

The fluid reservoir in the charging and re-filling case may storemultiple dosages of e-liquid; the amount of e-liquid stored in thereservoir can be 10 ml and is hence significantly greater than the fluidin a conventional cartridge or vial inserted into a conventionalelectronic cigarette. This makes re-filling the case with a freshe-liquid cartridge far less frequent; with a conventional PV, thecartridge in the PV has to be replenished or replaced once thatrelatively small dose is consumed; with our approach, it is thecartridge slotted into the carrying case that has to be replaced andthis is readily done; as this holds far more than a conventional PVcartridge, replacement occurs far less frequently. Re-filling the PVoccurs easily and quickly whenever the user inserts the PV back into thecarrying case. This is not only more convenient for the end-user, butalso significantly reduces waste. The cartridges are ideally fullyrecyclable.

A high-capacity e-liquid cartridge that is easily user-replaceable isespecially important in a relatively low voltage, low resistance (e.g.closer to 3.3V than 5V; resistance closer to 2 ohms than 2.8 ohms orhigher—typically 2.4 ohms—1.9 ohms for 3.3V) since e-liquid consumptionby the PV can be quite high. This high consumption would, with aconventional PV design be highly inconvenient because of the need todisassemble the PV and manually drip e-liquid into a small reservoir bysqueezing a bottle of e-liquid. But it is no longer a problem because ofthe ease of re-filling the PV with e-liquid whenever it is slotted backinto the case.

A user is also now able to monitor use of the PV (and hence nicotineuse) in a similar way to conventional cigarette consumption. Forexample, a single dose may be equivalent to the amount of e-liquidrequired to simulate nicotine consumption equivalent to a single tobaccocigarette. With the micro-pump system described later in this section,pressing the PV down just once against the micro-pump causesapproximately 0.1 ml to be transferred from the case to the PV; this isapproximately equivalent to ten puffs of a cigarette. The user couldhence pump the PV down just once to transfer e-liquid equivalent to asingle cigarette, or say five times for five cigarettes, or ten timesfor ten cigarettes.

In one design, the volume of e-liquid stored in the PV chamber may beequivalent to the volume of e-liquid required for an electroniccigarette to simulate a pack of twenty tobacco cigarettes. Therefore,the user may be able to conveniently regulate their consumption ofnicotine via the PV. The maximum capacity of the e-liquid chamber in thePV could be 2 ml, and hence very approximately equivalent to twentycigarettes. This easy to understand equivalence to conventionalcigarettes is important in enabling users to gauge their useage andhence important for nicotine reduction useage; users find correlatinguseage of conventional e-cigarettes to their previous tobaccoconsumption difficult and this lack of transparency inhibits broaderadoption of e-cigarettes, despite the significant body of scientificopinion that holds e-cigarettes to be very considerably safer thanconventional cigarettes.

A single dose may also be any other quantity set as equivalent to asingle dose, for example by the end-user, or automatically by the PV orits case if for example the end-user is following a nicotine reductionprogram. This generalisation applies throughout this specification andto all of the various innovative features described in it.

Embodiments may provide a rechargeable case battery where the portablecharging and re-filling case is adapted to allow the PV to recharge itsbattery from the rechargeable case battery. The portable charging andre-filling case may offer the advantage that a user is able tosimultaneously refill the PV with e-liquid and also recharge the batteryof the PV. This ensures that, whenever the PV is withdrawn from thecase, it can have sufficient e-liquid and power to provide a good vapingexperience.

The portable charging and re-filling case may comprise a PV holder forhousing the PV. The holder may support the PV in a specific position,provide storage, and enable refilling and charging of the PV.

The PV holder may comprise a biasing means for receiving a PV in asupport position. The biasing means may be arranged such that depressingthe PV causes the biasing means to allow the PV to engage with therefill mechanism, in a refill position. To refill the PV with a dose ofvapour liquid the PV may be inserted into the holder. The holder may bea drawer such that when the PV is placed in the drawer, pushing the PVdown allows the PV to engage with the refill mechanism so that e-liquidis pumped into the PV, filling the e-liquid chamber of the PV with onedose of e-liquid.

Alternatively, the PV holder may be rotatably connected to the portablecharging and re-filling case such that the PV holder can move between anopen and closed configuration, the open and closed positions havingcorresponding PV positions, wherein in the closed configuration the PVengages with the refill mechanism to receive a dose of e-liquid and inthe open configuration the PV is disengaged from the refill mechanism.

The refill mechanism may comprise a pump. In such an example,interaction between the PV and the refill mechanism may cause the pumpto deliver a measured dose of e-liquid to the PV. The refill mechanismmay comprise a refill valve. The refill mechanism may be electronicallycontrolled. A more detailed walk-through of the e-liquid transfermechanism will be given later.

The portable charging device or case may comprise a counter/measuringsystem for counting the number of times the PV has been refilled fromthe e-liquid reservoir. The counter may be resettable and the portablecharging and re-filling case may display a value provided by the countercorresponding to the number of times the PV has been refilled from thee-liquid reservoir in the case. The value may be the number of times thePV has been refilled from the reservoir since the last time it wasreset, or it may be the total number of times a dose of e-liquid hasbeen supplied by the reservoir by the refill mechanism. The data may bedisplayed or stored on a processor within the portable charging andre-filling case to be transmitted by wire or wirelessly to a secondarydevice for analysis and display, such as a smartphone, a wearabledevice, a portable computer or directly to the internet. Further,monitoring of usage may be used to determine when the e-liquid in thereservoir is nearly depleted and thus prompt the replacement of thefluid reservoir (by automatically ordering a replacement (or a week or amonth's worth of replacements, or some other quantity, at the user'soption) from an e-fulfilment platform that will then deliver direct tothe user, or advising the user that a replacement will be needed, forexample).

Embodiments may be further adapted to vary the amount of e-liquid in asingle dose, and such variation may be based on prior usage of the PV(as monitored by a counter for example). In this way, the amount ofe-liquid (or the concentration within the vapour fluid) in a delivereddose may be gradually reduced over time, helping a user to reduceconsumption of a substance in the vapour fluid (such as nicotine orcaffeine, for example). Such a concept may be extended to enabling auser to indicate a time period over which they wish to reduceconsumption and by how much. Based on such an indication, an embodimentmay moderate the amount of e-liquid in a single dose such that thedesired reduction in consumption is achieved automatically, and over aset period of time or following a specific cessation program.

The e-liquid reservoir may be a liquid cartridge which is removable fromthe portable charging and re-filling case such that it can be easily andquickly replaced by a user, without mess or risk of spillage. Therefore,when the e-liquid reservoir is depleted a user may insert a new liquidcartridge so that the reservoir is replete.

The PV may comprise a liquid chamber for holding a dose of e-liquid,wherein the PV is adapted to engage with the portable charging andre-filling case in order to receive a dose of e-liquid from the fluidreservoir. The PV may comprise a PV valve.

Engagement of the PV valve and refill valve may allow a dose of e-liquidto be pumped from the reservoir of the portable charging and re-fillingcase to the fluid chamber of the PV. Therefore, when the PV is in ormoved to a refill position, a dose of e-liquid may be delivered to thePV. When the PV is not engaged with the refill mechanism, the PV valvemay be closed so that the e-liquid is stored in the PV.

In the following section, we will describe the PV and case, withreference to the Figures.

Referring to FIGS. 6 and 7, there is shown a portable charging andre-filling case 100 according to the invention. The portable chargingand re-filling case 100 houses a fluid reservoir 3 and a rechargeablecase battery 68 both of which are user-removable and replaceable. The PVholder or receptacle chassis 2 is a holder that is sized to securelyhold the PV 1; it is shown in an open configuration and is adapted tostore the electronic cigarette 1 or any other PV in a specific positionthat enables the PV 1 to accurately engage with and align againstelectrical charging contacts, data transfer contacts and e-liquidre-filling nozzle that are all in the case. The PV holder or receptaclechassis 2 in this embodiment is pivotally attached to the main body ofthe portable charging and re-filling case 100 such that in a closedconfiguration the PV 1 is stored securely within the casing of theportable charging and re-filling case 100.

In use, the e-cigarette PV 1 is placed in the electronic PV holder orreceptacle chassis 2 and the chassis 2 is then moved to the closedconfiguration in order to store and/or refill the e-cigarette PV 1. Inthe closed configuration, the electronic cigarette 1 is in a refillposition and can be depressed to engage with a fluid transfer mechanismto receive a dose of e-liquid from the fluid i.e. e-liquid reservoir 3in the case 100 (typically, 0.1 ml is pumped across, as noted above, foreach downwards pumping action). Alternatively, the electronic cigarette1 may be refuelled upon insertion into the PV holder 2 using some otherfluid transfer action, such as a pressurised pump, electrical pump,peristaltic pump etc.

The electronic cigarette 1 may also recharge not only its e-fluidchamber but also its internal battery 59 from the recharge case 100.This offers a user an advantage, in that it is no longer necessary tocarry spare cartridges of e-liquid in order to refill the electroniccigarette 1 with e-liquid, or spare batteries to power the PV, asre-filling and re-charging can be achieved directly and without messfrom the portable charging and re-filling case 100.

FIG. 7 shows, at a schematic level, an example of the portable chargingand re-filling case 100 in cross section, and an electronic cigarette 1for use with the portable charging and re-filling case 100. The e-liquidchamber of the electronic cigarette 1 is adapted to receive and store asingle dose of e-liquid fluid. The reservoir 3 of the portable chargingand re-filling case 100 stores multiple doses of e-liquid and isconnected to a dosed pump 4. The pump 4 includes a valve 34 and valveseals 13 & 14 and a bias spring 87. When the pump 4 is actuated, a doseof e-liquid is delivered from the portable charging and re-filling case100 to the e-liquid chamber of the electronic cigarette 1 through hollowshaft 61.

The electronic cigarette 1 is placed into the PV holder 2 in a supportposition. In the support position, the electronic cigarette isdisengaged from the refill mechanism. In an embodiment, a biasing member87 prevents the electronic cigarette 1 from engaging with the refillmechanism 4 such that the electronic cigarette is maintained in thesupport position.

To actuate the pump 4, the electronic cigarette 1 is depressed.Depression of the electronic cigarette 1 overcomes the biasing forceprovided by the biasing member 87 and enables the electronic cigarette 1to move to a refill position, or to re-fill by virtue of being depresseddownwards.

When refilling, the electronic cigarette engages with the refillmechanism 4 to receive a dose of e-liquid. A counter (not shown; part ofthe electronics in the case) monitors the number of doses dispensed bythe refill mechanism 4 and displays the value on a display in the case,and/or transmits by wire (e.g. USB) or wireless (e.g.. Bluetooth) theusage data to a secondary device (e.g. a smartphone) with a display, tothe user. The counter may display the number of doses dispensed by therefill mechanism 4 since the counter was last reset and/or may displaythe total number of doses the refill mechanism 4 has dispensed. Thisoffers the user the advantage of having the opportunity to monitor theirconsumption. The counter may indicate to a user when the fluid reservoir3 holds a lower volume than a threshold value (e.g. when the vapourfluid in the reservoir is nearly depleted).

Detection that the amount of vapour fluid in the reservoir is below thethreshold value may be used to prompt the replacement of the fluidreservoir, by automatically ordering the delivery of a replacement fluidreservoir for example.

In the FIG. 7 schematic, the chassis 2 is just a holder for the PV andthe pump 4 mechanism; in the more detailed walk-through of the workingdevice we will provide later in this Section A (e.g. FIGS. 21-26) thechassis also supports the case battery, electronics and e-liquidreservoir; this simplifies the connection between pump and e-liquidreservoir, eliminating the need for a flexible e-liquid pipe.

FIG. 8 illustrates a further example of the portable charging andre-filling case 100 in use. Here, the PV holder 2 is rotatably connectedto the portable charging and re-filling case 100 and swivels to an openconfiguration to accept the electronic cigarette 1. In order to refillthe electronic cigarette 1 with e-liquid, the electronic cigarette 1 isplaced into the PV holder 2 when the PV holder 2 is in the openconfiguration. The PV holder 2 is then moved to a closed configuration.The position of the electronic cigarette 1 in the closed configurationis such that the electronic cigarette 1 engages with the refillmechanism 4 to receive a specific or predetermined dose of e-liquid.

FIG. 9 shows the interaction between the electronic cigarette 1 and therefill mechanism 4 in more detail. The refill mechanism 4 includes ahollow stem shaft 61 which engages with the electronic cigarette 1 whenthe electronic cigarette 1 is in the refill position. Pushing the PV 1down, into the refill position causes vapour fluid to be pumped from thefluid reservoir 3 to the electronic cigarette 1. In an example, therefill mechanism 4 is electronically controlled. For example, the pump 4may be actuated or the refill valve 34 may open in response to areceived signal.

FIG. 10 shows the electronic cigarette 1 stored in the portable chargingand re-filling case 100 in the refill position. When the PV holder 2 isin the closed configuration, e-liquid is pumped from the fluid reservoir3 to the liquid chamber of the electronic cigarette 1 to refuel theelectronic cigarette 1. For example, this can be achieved by the top 32of the PV being pushed downwards by a camming action as the holder 2 isclosed, overcoming bias spring 87. Or an electronic pump might beactivated once the PV is in the closed configuration. Also, theelectronic cigarette 1 may recharge its battery 59 from the rechargeablecase battery 68 of the portable charging and re-filling case 100.

Referring to FIG. 11, there is shown an electronic cigarette 1 for usewith the portable charging and re-filling case 100. The electroniccigarette 1 has a liquid chamber 48 for storing a dose of e-liquid. Theliquid chamber is connected to a PV valve 29. When the electroniccigarette 1 engages with the refill mechanism 4 of the portable chargingand re-filling case 100, the PV valve 29 opens to allow a dose ofe-liquid to enter the chamber 48. When the electronic cigarette 1 is notengaged with the refill mechanism 4, the PV valve 29 is closed so thatthe vapour liquid is stored in the liquid chamber and does not leak out.

It will be appreciated that the portable charging and re-filling case100 is not limited in shape, and may not be rectangular. The refillmechanism 4 may not comprise a pump but some other kind of fluidtransfer mechanism, and refilling of the electronic cigarette 1 withelectronic cigarette fluid may be achieved by an alternative means.Further, the charging function may also occur using a charging stationthat is fixed (e.g. desktop based; plugged into a power socket) ratherthan using a portable charging and re-filling case.

For example, referring now to FIGS. 12 and 13 there are shown modifiedembodiments where the PV holder 2 is not rotatably connected to theportable charging and re-filling case 100. More specifically, FIG. 12shows an embodiment where the PV holder is formed as a recess in theside the portable charging and re-filling case 100. The recess isadapted to receive a PV 1.

FIG. 13 shows an alternative embodiment wherein the PV holder is formedas a cylindrical hollow barrel along the central longitudinal axis of acircular portable charging and re-filling case 100. A PV may be placedinto the hollow barrel in a support position (as depicted in FIG. 13,left hand-side). In the support position, the PV is disengaged from therefill mechanism.

In an embodiment, a biasing member not shown prevents the PV fromengaging with the refill mechanism such that the PV is in a supportposition. To actuate the refill mechanism of the portable charging andre-filling case 100, the PV is pushed further in to the hollow barrel.Such further depression of the PV overcomes a biasing force provided bya biasing member and enables the PV to move to a refill position asdepicted in FIG. 13, right hand-side.

In the refill position, the PV engages with the refill mechanism toreceive a dose of e-liquid from the reservoir of the portable chargingand re-filling case 100.

FIG. 14 shows that when the e-cigarette PV is depressed down onto therefill nozzle of the case, then case charge contacts electricallycontact e-cigarette PV charge contacts, electrically connecting theelectronic cigarette to the case battery so that the electroniccigarette can recharge its internal battery from the rechargeable casebattery; hence, both the PV's battery as well as its e-liquid reservoirare replenished when inserted into the case. The electronic contacts canalso provide the mechanisms through which the data is transferred fromthe PV to the portable case.

Non-pressurised pump technology can be used in this design to dispense adose of a given volume of e-liquid. The device is made up of a singlepump with a hollow control tube. The pump has a chamber with apredefined volume of e-liquid held for dispensing. When the PV isdepressed, the e-liquid is forced under pressure from the e-liquid pumpout through the pump nozzle and via a one way valve into the PV chamber.As the pump is released, it returns to its original state under a springmechanism and in doing so draws liquid through the hollow control tubeinto the liquid chamber to replenish the pump so that it is ready totransfer e-liquid into the PV on the next down-stroke of the PV.

The pump is preferably a pump termed a “high delivery” pump, which makesit possible to fill the bottle by actuating the pump only once. Forexample, a pump is suitably used having a delivery of 0.1 ml per shot inorder to feed the PV chamber.

The pump dosage volume can be predefined or variable dependent uponusage requirements. For variable dosage the travel of the pump can bevariably limited with a screw type mechanism. e.g. half the normal pumptravel=half the liquid intake and therefore expelled.

Pressurised pump technology may also be used: the liquid cartridge wouldbe pressurised like a small aerosol to move predetermined volumes ofliquid. The vapouriser would depress a valve that contains a liquidchamber. As the system is pressurised no ‘pump’ is required, insteadfluid moves straight from the cartridge to the PV chamber, which isfixed in volume.

A Working System

In the following section, we will describe a working system. Forclarity, we will capitalize defined terms, which are indexed in theBrief Description of the Drawings section. The relevant figures areFIGS. 15-54. We suggest reviewing these Figures using the index ofdefined terms as a first step in understanding the system.

The system comprises several main components, a Personal Vaporiser 1 anda portable, personal re-filling and re-charging Case 100. FIG. 15 showsa working, test prototype (i.e. not with the industrial design finishingof the final consumer product). The remainder of the engineeringdrawings will also relate to this test prototype. The case 100 is shownwith a left hand side 6 and a right hand side 7. The case includes aReceptacle Chassis 2; the Receptacle Chassis 2 serves as the PV holder,securely holding the PV 1 when it is inserted into the case 6, 7. TheReceptacle Chassis also serves as the mount on which are placed thee-liquid reservoir 3, fluid transfer mechanism 4, battery 68 and relatedcomponents.

The entire Receptacle Chassis 2 rotates 15° about a Pivot Screw 18inside a Case 6, 7 with the Receptacle Chassis 2 being Positively BiasedClosed, 0° position, by a Leaf

Spring 17 (first shown in FIG. 21) attached to the Receptacle Chassis 2via Screws 35 (first shown in FIG. 21).

FIG. 15 shows an isometric view of the case 100 with the ReceptacleChassis 2 fully closed; FIG. 16 shows an isometric view of case 100 withthe Receptacle Chassis 2 rotated open 15° and showing the top of a PV 1fully inserted into the PV holder portion of the Receptacle Chassis 2.FIG. 17 shows an isometric view of the case 100 with PV 1 slightlyraised and ready for the user to withdraw from the case 100. The PV 1has been heated to its operational temperature using the battery in thecase and is ‘ready to vape’. FIG. 18 shows an isometric view of theReceptacle Chassis 2 on its own. FIG. 19 shows an isometric view of thePV 1 (again, note that this is the test prototype and not the consumerversion). The PV 1 has a Tip 32; at the end of the Tip 32 is a centrallypositioned aperture through which e-fluid passes when re-filling the PV1. A Seal Inlet 27 seals the aperture against the pump nozzle of thefluid transfer mechanism to prevent spillage or leakage of e-liquid.Three radially disposed vents are positioned around this centralaperture; these are the vents through which vapour is inhaled. A RingConnector Assembly 49 at the other end of the PV 1 provides electricalpower and data contacts that engage with electrical power and datacontacts in the Case 100. Tube body 56 contains all components.

FIG. 20 shows a sectioned view of the PV 1. Starting from the left-handside, Seal Inlet 27 seals the PV against a fluid transfer nozzle in thecase; Valve 29 enables e-liquid to pass up into the PV and prevents itleaking out since it is biased in the closed position by Spring 30.Valve 29 only opens when the force exerted by the fluid, driven by thefluid transfer mechanism, exceeds the force of Spring 30. Grub screws 31secures the Valve 29 and Spring 30 in position. An O-Ring 28 seals Tip32 against the body of the PV 1. The atomiser includes a Coil and WickAssembly 52 with a Vapouriser End Cap 50 and Vapouriser InsulatingSleeve 51. Fluid Chamber 48 stores e-liquid; the lengths of wickingelement running parallel to the body of the PV are fully immersed ine-liquid in Fluid Chamber 48; the wicking element running perpendicularto the body of the PV, and around which the electrical heating elementis wound, is not however immersed in e-liquid, but draws e-liquid upfrom the limbs that are fully immersed. Further O-Ring 28 seal thee-liquid Chamber 48 from the rest of the Tube Body 56 of the PV 1. TheOuter Body 53 of the PV surrounds the vapouriser.

Vaporiser Outer Body 53 and Vaporiser Inner Body 55 are insulated byBush Vaporiser Body 54. Current is passed to the Vaporiser Inner Body 55via a wire connected to PCB 60. One leg of the Coil 52 contacts theVaporiser Inner Body 55, the other Coil Leg contacts Vaporiser OuterBody 53. This can be seen most clearly from FIG. 48. The Vaporiser OuterBody 53 is connected to Earth.

A Pressure Sensor/Transducer 58 is mounted behind the Vaporiser Unit inthe Pressure Sensor Housing 57. This is wired to the PCB 60. An ArduinoChip 66 mounted to the PCB 60 is used to monitor, control, set andfeedback information pertaining to the vaping functionality.

A 3.7V 140 mAh LiPo Battery 59 sits on the PCB 60. The far end of thePCB 60 is wired to Ring Connector 49 with 4 connections—1 Power, 1Earth, 2 Signal. Ring Connector 49 is made up of alternating RingContacts 42 and Insulation Rings 43, and is mounted on Screw 44 andterminates with End Cap 36.

When air is drawn through the PV 1, the Pressure Sensor/Transducer 58activates, causing current to be sent to the Coil/Wick Assembly 52. TheCoil heats the vaping fluid soaked wick, giving off vapour whichentrains into the air stream.

O rings 28 seal the Vaping Chamber 48 from the air path. A unitary (andhence very strong) stainless steel Tube 56 houses all the partsmentioned above with a cut out to allow the RGB LED 64 to display theStatus of the PV 1 for both battery power and vaping fluid level. Afurther small hole sits above the Reset Switch 65 mounted to the PCB 60.

The PV 1 charges its 140 mAh Battery via the Ring Connector 49.Information is also fed back to the PCB Main Case 16 via 2 of theconnections on the Ring Connector 49.

If we look now at FIG. 21, we see a sectioned view of the case 100 withthe Receptacle Chassis 2 fully closed into the case 100; the PV 1 isomitted for clarity. FIG. 22 shows a sectioned view of case 100 with theReceptacle Chassis 2 rotated open 15, again with no PV inserted forclarity. To Load/Insert PV 1 into Receptacle Chassis 2 hand pressure isapplied to the Lower Section of the exposed Receptacle Chassis 2.Receptacle Chassis 2 rotates 15°, using hand pressure, from its closedposition, shown in FIG. 21, to its “Open” position shown in FIG. 22,with Leaf Spring 17 supplying a resistive force, bearing against Case 6& 7 inner walls.

FIG. 22 shows clearly how all critical components needed in the case 100are mounted on the Receptacle Chassis 2. Key elements are the e-liquidpump 4, which sits in a void in the e-liquid cartridge 3. A hollow stemshaft 61 protrudes from one end of the pump 4, biased upwards by aspring; when a PV is depressed against this hollow stem shaft 61, itdepresses that hollow stem shaft 61 downwards, forcing e-liquid withinthe pump 4 to travel up the hollow stem shaft 61 into the PV; thee-liquid cannot return back into the reservoir 3 because a ball valve 34at the base of the pump 4 closes. Also mounted on the Receptacle Chassis2 is the rechargeable battery 68 and a solenoid 22 that triggers aninterlock mechanism, a lever or pawl 10 with a tooth at one end thatrests against a sliding contact block 5. When the sliding contact block5 fully engages with the PV, the pawl rises and locks against an edge ofthe sliding contact block 5, preventing it from moving back into thecase 100 and hence locking the PV into position. Various PCB componentsare also shown mounted on the Receptacle Chassis 2, such asMicroswitches 70, and PCB 16. Leaf Spring 17, mounted against ReceptacleChassis 2 with Screws 35, biases the Receptacle Chassis 2 in a closedposition, as shown in FIG. 21; it is shown in its opened position inFIG. 22.

Moving to FIG. 23, we now see the PV 1 fully inserted into ReceptacleChassis 2, which is fully closed within the case 100. The PV 1 isretained in position by a small ridge in the top of the sliding contactblock 5 that engages with a channel around the top of the PV 1.

-   -   There is no power from Receptacle Chassis 2 to Coil & Wick        Assembly 52 or Solenoid 22. The system is in standby mode.    -   Receptacle Chassis 2 is at closed 0° Position    -   Pawl/Lever 10 is in its disengaged position, biased 6° to the        horizontal by Spring 19    -   4 Way Sliding Contact Block 5 is pushed into contact with Ring        Connector Assy 49 by Cam Block 8—the action of rotating        Receptacle Chassis 2 to Closed 0° position advances the 4 Way        Sliding Contact Block 5 against Spring 23 (see FIGS. 27-30 for        more details on the operation of the 4 Way Sliding Contact Block        5.

FIG. 24 shows the device in activated mode, with solenoid 22 activatedand pawl/lever 10 activated, locking sliding contact block 5 inposition.

-   -   Power is supplied from Receptacle Chassis 2 to Solenoid 22.        Power is supplied to Solenoid 22 when a small angular        displacement of Receptacle Chassis 2 relative to Case 6 & 7        activates a Micro-switch 70 attached to Case 6 & 7    -   Receptacle Chassis 2 is at the closed 0° Position.    -   Pawl/Lever is pushed up into its engaged position, 0° to the        horizontal, by

Solenoid 22, locking the 4 Way Sliding Contact Block 5 into electricalcontact with Ring Connector Assembly 49 (see FIGS. 27-30 for moredetails on the operation of the 4 Way Sliding Contact Block 5). Amechanical interlock between 4 Way Sliding Connector Block 5 and PV 1 istherefore engaged.

FIG. 25 shows the pre-heat mode: the Receptacle Chassis 2 is now fullyopened; the PV 1 is locked in position and the sliding contact block 5is also locked in position by pawl/lever 10; current is drawn from casebattery 68 to heat the coil in the Coil and Wick Assembly 52 in PV 1.

-   -   Power is only supplied from Receptacle Chassis 2 to Coil & Wick        Assembly 52 when the Receptacle Chassis has rotated fully to its        15° to its Open position.    -   Pawl/Lever pushed into its engaged position, 0° to the        horizontal, by Solenoid 22    -   The 4 Way Sliding Contact Block 5 is in electrical contact with        Ring Connector Assembly 49. (See FIGS. 27-30 for more details on        the operation of the 4 Way Sliding Contact Block 5).    -   The mechanical Interlock between 4 Way Sliding Connector Block 5        and PV 1 continues to be engaged.

Once pre-heating is completed, solenoid 22 releases pawl/lever 10 andsliding contact block 5 withdraws away from the PV 1, which is thenbiased to rise up slightly out of the case 100 by shaft 61 in pump 4, asshown in FIG. 26. So FIG. 26 shows the activated mode.

-   -   No power is supplied from Receptacle Chassis 2 to Coil & Wick        Assembly 52 or Solenoid 22.    -   Receptacle Chassis 2 is at Open 15° Position with PV 1 standing        3 mm proud    -   4 Way Sliding Contact Block 5 is disconnected from Ring        Connector Assembly 49 under pressure from Spring 23. (See FIGS.        27-30 for more details on the operation of the 4 Way Sliding        Contact Block 5).    -   Pawl/Lever 10 is in its disengaged position, biased 6° from the        horizontal by Spring 19    -   Mechanical interlock between 4 Way Sliding Connector Block 5 and        PV 1 is now disengaged.

FIGS. 27-32 show the operation of the 4 Way Sliding Contact Block 5.

The 4 Way Sliding Contact Block 5 connects Power, Earth and 2 SignalInput/Outputs from the PCB Main Case 16 to the PV PCB 60. A mechanicalInterlock between the 4 Way Sliding Contact Block 5 and the PV 1 isincorporated in the design: the body 46 of the 4 Way Sliding ContactBlock has a finger protrusion which engages with an undercut on the PVring connector 49 providing the interlock facility. This is clearestwhen comparing FIGS. 27-29, which show the finger protrusion lockinginto the PV, and FIG. 30, which shows the 4 Way Sliding Contact Block 5after it has slid back into the case and the PV 1 is now released.

The 4 Way Sliding Contact Block 5 is normally biased away from and outof contact with the Ring Connector 49 on the PV by a helical Spring 23when mounted in the Receptacle Chassis 2 in the Open 15° position andwith the Pawl/Lever in the disengaged 6° position—FIG. 30.

The 4 Way Sliding Contact Block 5 is pushed into contact with the PVRing Connector 49 when the Receptacle Chassis 2 is rotated back into theCase 6 & 7 to the Closed 0° position—e.g. when storing the PV, as shownin FIGS. 27-28.

A Cam Block 8 is fastened to the Case 6 & 7. When the Receptacle Chassis2 rotates into the Case 6 & 7 the Spring 23 biasing the 4 Way SlidingContact Block 5 is compressed as the 4 Way Sliding Contact Block 5 bearsagainst the Cam Block 8.

The 4 Way Sliding Contact Block comprises 4 Contact Fingers 24—FIGS. 31and 32 show these clearly, housed in Body—4 Way Sliding Contact Block 46and five Support Rings 45. Four wires are connected to the ContactFingers 24. These connect back to pads on PCB Main Case 16. The 4 WaySliding Contact Block 5 is limited to 2 mm in its linear travel by GuidePlate 9.

FIG. 33 is an exploded view of the case 100 and its components, thedetailed operation of which has been described above. The ReceptacleChassis 2 forms the main housing for all the major components. When thedevice is built a Cover 12 is screwed into place. The Receptacle Chassishouses the PCB Main Case 16. This has a 650 mAh battery 68 connected toit and a Micro USB Connector 67 for re-charging the main battery andcommunications. The PCB Main Case 16 fastens to the Receptacle Chassis 2by means of PCB Standoffs 69. These also serve as the fixing holes forthe Lid 12. Solenoid 22 is attached to the Receptacle Chassis 2 via theSolenoid Mounting Block 11, adjustment is provided via a slotted screwhole in the Solenoid Mounting Block 11. The PCB Main Case 16 has anArduino Chip mounted to it controlling all electrical functionsassociated with the device. Consequently, it is possible for the user toalter the power delivered to the atomiser and hence customise the vapingexperience to their specific preferences. The Arduino Chip can becontrolled from a connected smartphone app., communicating with theArduino Chip over Bluetooth LE. The following kinds of data could betracked by the Arduino Chip and relayed to the user's connectedsmartphone app.:

-   -   How many times the PV leaves the case    -   Duration of PV out of case    -   Internal clock used by the Arduino Chip stores data relative to        first use, i.e. if unconnected for a few days it stores the data    -   On pairing with phone GPS and time data    -   Number of inhalations    -   Duration of each inhalation    -   Frequency of inhalation    -   Depth of inhalation    -   Power provided to the atomizer    -   Current and/or voltage provided to the atomiser    -   Battery power level—case and PV    -   Number of times PV has been inserted and/or withdrawn from the        case    -   Number of times the PV has been pumped to re-fill it with        e-liquid    -   Vapes remaining (calculation from data)    -   Cartridge e-liquid volume remaining—(calculation from data).    -   Whether a fresh cartridge should be ordered    -   Instruction to order a fresh cartridge    -   Type of e-liquid used (e.g. strength, flavor, mixtures of        different e-liquids)    -   Unique ID in case and PV, so that the Case will only work with a        designated PV

It would be possible also to include power control buttons, dials etc onthe Case 100 itself, although this would add to complexity and cost. ADisplay is provided in the Receptacle Chassis to communicate the Devicestatus to the user.

We will now look at the details of the fluid transfer mechanism. Therelevant figures are FIGS. 34, 35 and 36.

Fluid transfer operation is as follows: the PV 1 is dropped into theReceptacle Chassis apertures 2 where it comes to a stop against the topof the Pump 4. Depressing the PV 1 further against the Pump 4 causes afurther 3 mm linear travel & the transfer of a metered dose of e-liquidvaping fluid from the Receptacle Chassis 2 to the PV 1. Approximately0.1 ml of e-liquid is transferred per pumping action. The reservoir inthe PV can typically store 1 or 2 ml of e-liquid. The PV 1 Fluid Chamber48 can be charged by repeatedly pushing the PV 1 down against the Pump4.

Relaxing hand pressure on the lower section of the Receptacle Chassis 2allows the Receptacle Chassis 2 to return to its closed 0° positionunder the Leaf Spring 17 force, closing the PV 1 into Receptacle Chassis2 for secure storage. The device geometry ensures the top of the PV 1Cams it in a downward direction against the top inside walls of the Case6 & 7 when the Receptacle Chassis 2 is returned to its 0° closedposition.

The case 100 can accept a custom designed 5 ml Fluid Reservoir 3 whichcan be fitted and withdrawn from the Receptacle Chassis 2 by pushing inand pulling out. Other sizes of Fluid Reservoir 3 are also possible,typically up to 10 ml. It is retained by means of a Moulded Rim 62 andSealed to the Pump 4 my means of an integrally Moulded Lip Seal 63.Different types of Vaping Fluid can be easily changed with nodisassembly of the Device required.

FIG. 34 shows the loading—discharging position, with the ReceptacleChassis 2 at the Open 15° position. Pump 4 is mounted into ReceptacleChassis 2 and is sandwiched between Valve Mounting Cup 13 & ValveMounting Cap 14. Reservoir 3 pushes into a slot in Receptacle Chassis 2from beneath, with Moulded Rim 62 snapping into an undercut section inReceptacle Chassis 2. Reservoir Gasket 15 applies pressure on MouldedRim 62 to maintain contact with the undercut. Reservoir 3 can be readilyinserted and withdrawn by the user. Reservoir 3 has moulded Lip Seal 63as an integral feature which seals against Pump 4. PV 1 is restingagainst Hollow Stem Shaft 61 of pump 4, but has not yet started todepress the Hollow Stem Shaft 61.

FIG. 35 shows the re-filling position—with Receptacle Chassis 2 still atthe Open 15° position. PV 1 is now shown flush with Valve Mounting Cup13 & Pump 4. Hollow Stem Shaft 61 has been depressed down 3 mm by the PV1. Fluid passes up Pump 4 Hollow Stem Shaft 61 and Opens Valve 29 in PVTip 32. Seal 27 bears against top of Pump 4 Hollow Stem Shaft 61. Valve29 is moved off its seat by the pressure of the transferring e-liquidfluid. Spring 30 returns Valve 29 to its seat after pressure hasequalised with Vaping Fluid entering Fluid Chamber 48.

FIG. 36 shows the standby position—Closed 0° position. Hollow Stem Shaft61 is fully depressed and PV 1 is in a dormant state. E-liquidpreviously pumped into the PV 1 is retained with the PV 1, so that itremains ready to use.

The detailed operation of the pump 4 will now be described. The relevantfigures are FIGS. 37, 38, 39 and 40.

FIG. 37 shows pump 4 at its start position, ready for initial priming.

The pump 4 has a non-return ball valve 34 at fluid inlet end 81 and aslide valve at fluid outlet end 82. The non-return ball valve 34consists of a steel ball bearing that moves within a short slotted tube83 with retaining barbs at one end and seats into a shallow taper at theother end, closest to the fluid inlet end 81.

The slide valve consists of a through-hole 84 in the piston rod 86 whichis covered and revealed by the action of the piston 85 sliding backwardsand forwards over the through-hole 84.

The pump has a piston assembly comprising a valve stem 88, a piston rod86, a piston 85 and a bias spring 87. The valve stem 88 and piston rod86 are permanently joined together and move as one. The piston 85 slideson the piston rod 86 and in the valve stem 88. A bias spring 87 keepsthe piston 85 positioned forward, at the start position of its 3 mmstroke, and covering the slide valve through-hole 84.

Exerting an axial force on the pump's valve stem 88 (e.g. as occurs whenthe PV 1 is pressed downwards into the Receptacle Chassis 2), causes thepiston assembly to move forward inside the pump body, hence pressurisingthe fluid ahead of the piston 85 in the fluid chamber 80. Non-returnball valve 34 prevents fluid simply discharging back into the fluidreservoir 3.

As the hydraulic pressure increases, it overcomes the force exerted onthe piston 85 by the bias spring 87, hence allowing the piston to movebackwards relative to the piston rod 86.

FIG. 38 shows the piston 85 at the end of its 3 mm stroke; the biasspring 87 is now fully compressed, by 1.2 mm. Piston return spring isnow also fully compressed, by 3 mm. The feed though-hole 84 in thepiston rod 86 is exposed since the piston 85 has been forced backwardsrelative to the piston rod 86 by the increased hydraulic pressure, whichexceeds that of the bias spring 87.

The pressurised fluid in the fluid chamber 80 can now escape through theexposed feed-through hole 84 and up the inside of the piston rod 86 andvalve stem 88, as the piston assembly completes it's stroke.

A metered volume (0.1 ml) of e-liquid escapes into the PV 1 as thepiston assembly reaches the climax of it's stroke.

FIG. 39 shows that as the hydraulic pressure drops below the bias springforce, this allows the piston 85 to slide forwards along the piston rod86 and cover the feed-through hole 84. Fluid chamber 80 is now sealed atboth ends.

FIG. 40 shows removing the axial force on the valve stem; this allowsthe piston return spring 89 to send the piston assembly back to it'sstart point. As the piston assembly moves back to it's start point, avacuum develops in the pump fluid chamber 80. This pulls the non-returnball valve 34 off it's seat, allowing fluid from the reservoir to fillthe void in fluid chamber 80.

The pump cycle is now complete. (As a preliminary step, cycling thepiston assembly several times may be needed to dispel air from the fluidchamber 80 and replaces it with fluid. The fluid chamber 80 is nowcharged).

It is possible also to integrate the pump directly into theuser-replaceable cartridge. That has some advantages—specifically, ifthe pump fails, then it is just the cartridge that needs to be replaced,not the entire case. Also, if the pump is part of the case, anddifferent flavours of e-liquid are desired, that requires differentcartridges to be swapped in to the case. There may some residue of theprevious flavour in the pump, possibly affecting the vaping experience.Integrating the pump into the cartridge eliminates the problem offlavour tainting through previous e-liquid residue in the pump.

This variant is shown in FIGS. 41-45. The same 0.1 ml pump is used andit operation is fundamentally as described above. The fluid reservoir 3has a 5 ml capacity and is formed as part of a body moulding. The bodycavity is sealed with a valve cap 90 moulding, being ultra sonicallywelded to the body. Valve cap 90 at the fluid outlet end of the combinedpump and cartridge locks the pump in position and also provides guidancefor the valve stem 61.

The combined pump and cartridge includes an overflow valve. This is madeup of a tapered valve seat 91 in the body moulding, a steel ball bearing92 and return spring 93. The tapered valve seat 91 is at the end of abore slightly larger than the bore of the steel ball bearing 92. Thereare channels cut into the bore to allow for the flow of fluid in thebypass condition. The taper is 180° juxtaposed from the non-return valvetaper.

In normal operation, the overflow valve ball 92 remains seated in it'stapered housing kept in place by the return spring 93. If a conditionarises where the hydraulic pressure in the pump fluid chamber 80 exceedsthe design pressure, the overflow valve ball 92 is forced off it's seatagainst resistance offered from the return spring 93. Fluid can pass thesteel ball 92 and return to the reservoir chamber 3—this is the bypasscondition.

The integrated pump/reservoir/overflow valve can be in one of fivedifferent conditions:

Start position—as shown in FIG. 41.

-   -   pump fluid chamber 80 is in charged state. p1 Non-return valve        ball 34 is seated in it's tapered housing.    -   overflow valve ball 92 is seated in it's tapered housing.    -   pump piston assembly is covering slide valve fluid feed through        hole 84.    -   fluid in pump fluid chamber 80 is in a sealed state.

Open position—as shown in FIG. 42

-   -   pump piston assembly is travelling through it's 3 mm downstroke.    -   hydraulic pressure inside pump fluid chamber 80 has overcome the        bias spring 87 force allowing upward movement of piston 85.    -   slide valve has opened, allowing flow of fluid from pump fluid        chamber 80 to fluid outlet port 82 via fluid feed through hole        84.    -   non-return valve 34 remains closed    -   overflow valve 92 remains closed

Down position—as shown in FIG. 43

-   -   bias spring 87 has closed slide valve with piston 85 covering        fluid feed through hole 84.    -   fluid chamber 80 volume of fluid has been depleted by 0.1 ml.    -   remaining fluid in fluid chamber 80 no longer pressurised.    -   piston return spring 87 is compressed and exerting an upward        force on piston assembly 85.

Bypass position (this is conditional on the hydraulic design limit beingexceeded and hence protects against damaging the pump 4 and the PV 1)—asshown in FIG. 44

-   -   slide valve is in the open position, with piston 85 not covering        fluid feed through hole 84.    -   hydraulic pressure inside pump fluid chamber 80 and valve stem        88 exceeds design pressure.    -   non-return ball valve 34 is closed.    -   pressure relief overflow valve 92 opens against pressure from        return spring 93. Ball valve 92 is forced off it's seat by        excessive hydraulic pressure in the pump fluid chamber 80. Fluid        flows around ball valve 92, through channels and back into        reservoir 3.    -   once sufficient volume of fluid has been expelled from pump        fluid chamber 80 into reservoir 3, the hydraulic pressure        diminishes in pump fluid chamber 80, allowing pump piston        assembly to complete it's stroke. The bias spring 87 pushes the        85 piston over fluid feed-through hole 84, closing the sliding        valve.    -   pump is now in “down” condition.    -   both “open” and “bypass” positions precede “down” position.

Return position—as shown in FIG. 45

-   -   axial force has been removed from valve stem 88.    -   pump piston assembly returns to it's start position under return        spring 89 force.    -   a vacuum in the pump fluid chamber 80 develops in the wake of        the pump piston assembly returning to it's start position.    -   vacuum causes non-return valve ball 34 to move off it's tapered        seat, allowing fluid from the reservoir 3 to fill the void.    -   pump fluid chamber 80 is now charged and non-return valve ball        34 settles into it's seat.    -   pump is now in the start position.

We will now look closely at the PV 1 itself.

We earlier looked at a section view of the PV 1 (FIG. 20). FIG. 46 showsan exploded view of PV 1 and FIG. 47 shows an isometric view of PV 1.FIG. 48 shows one design of atomiser assembly. The PV 1 includes a PVTip 32 containing Valve 29, Valve Spring 30 and Grub Screw 31. PV Tip 32also has 3 concentric holes, connecting to Air Way, which allowVaporised Liquid to be inhaled. In this design of atomiser, the heatingcoil is perpendicular to the long axis of the PV 1. FIG. 49 shows analternative design in which the wicking material has the same ‘U’ shape,but also includes a long element running along the long axis of the PV1. Heating coil 98 is wound around this long element and the Coil & WickAssembly 52 then retained by chassis 99. The advantage of thisalternative design is that a longer heating coil 98 can be used, andairflow over the heated coil 98 should be more uniform and effectivesince the coil runs parallel to the airflow instead of perpendicular toit.

For both the perpendicular and parallel arrangements, the vaporiser sitsbehind the Tip 32, and is made up of a Coil & Wick Assembly 52,Vaporiser Outer Body 53 and Vaporiser Inner Body 55. These are insulatedby Bush Vaporiser Body 54. Current is passed to the Vaporiser Inner Body55 via a wire connected to PCB 60. One leg of the Coil 52 contacts theVaporiser Inner Body 55, the other Coil Leg contacts Vaporiser OuterBody 53. This can be seen most clearly from FIG. 48. The Vaporiser OuterBody 53 is connected to Earth.

A Pressure Sensor/Transducer 58 is mounted behind the Vaporiser Unit inthe Pressure Sensor Housing 57. This is wired to the PCB 60. An ArduinoChip 66 mounted to the PCB 60 is used to monitor, control, set andfeedback information pertaining to the Vaping Functionality.

A 3.7V 140 mAh LiPo Battery 59 sits on the PCB 60. The far end of thePCB 60 is wired to Ring Connector 49 with 4 connections—1 Power, 1Earth, 2 Signal.

When air is drawn through the PV 1, the Pressure Sensor/Transducer 58activates, causing current to be sent to the Coil/Wick Assembly 52. TheCoil heats the vaping fluid soaked wick, giving off vapour whichentrains into the air stream.

O rings 28 seal the Vaping Chamber 48 from the air path. A unitary (andhence very strong) stainless steel Tube 56 houses all the partsmentioned above with a cut out to allow the RGB LED 64 to display theStatus of the PV 1 for both battery power and vaping fluid level. Afurther small hole sits above the Reset Switch 65 mounted to the PCB 60.

The PV 1 charges its 140 mAh Battery via the Ring Connector 49.Information is also fed back to the PCB Main Case 16 via 2 of theconnections on the Ring Connector 49.

We will now look at the Ring Connector 49 in more detail. FIGS. 50 & 51are the relevant figures.

The Ring Connector Assembly allows the PV 1 to be placed in theReceptacle Chassis 2 in any orientation without it affecting itsconnectivity. Four Ring Contacts 42 with different length Pins 38, 39,40, 41 soldered to them are separated by three Insulating Rings 43 whichin turn are housed in End Cap—Ring Connector 36. This ensemble is cappedwith PCB Mounting Cap/Ring Connector 37 fastened with a Screw 44. A wireis soldered to each of the Pins 38, 39, 40, 41 which are then solderedto Pads on PCB 60. The Ring Connector Assembly also has 2 off 1.7 mmSlots which captivate the PV PCB 60. The Ring Connector Assembly is apush fit in the end of the Tube Body—Vaporiser 56.

We will now look at a variable air intake feature. Altering the airflowallows the user to customise the vaping experience to their specificpreferences; for example, an experienced vapour looking to produce largequantities of vapour with a variable voltage modding kit type PV mightset the voltage used to a much higher power than normal and he wouldmanually fix an air intake that would him to breath in a large volume ofvapour. Swapping different air-intakes is generally a matter of screwingout the unwanted air intake and screwing in an air-intake with therequired air-hole size(s). One variant of the PV has a variable airintake system in which the casing comprises an inner and an outer tube;the inner tube has a matrix of air-intake holes which can be lined upwith air-intake holes in an outer-tube; the user rotates the outer tubeuntil the desired number of holes are lined up. For example, the innertube could have a regular, square-arrangement or matrix of holesconsisting of 6 holes formed radially at 30° intervals repeated over 6rows. The outer tube then has a square matrix of holes consisting of 6holes formed radially at 30° intervals repeated over 6 rows. The outertube slides over inner tube until top rows of holes coincide. The outertube can be rotated in 30° increments to reveal 0, 1, 2, 3, 4, 5 or 6columns of holes in inner tube thereby varying cross sectional area ofair able to enter the vaporiser body. FIG. 52 shows two rows of holeslined up and FIG. 53 shows 5 rows lined up.

Another variant, shown in FIG. 54, comprises 2 tubes—inner and outer.The inner tube has a square matrix of holes consisting of 6 holes formedradially at 30° intervals repeated over 6 rows. The outer tube hashelical matrix of holes consisting of 1 hole per row formed radially at30° intervals repeated over 6 rows-6 holes in total. The outer tubeslides over inner tube until top rows of holes coincide. The outer tubecan be rotated in 30° increments to reveal 0, 1, 2, 3, 4, 5 or 6 columnsof holes in inner tube thereby varying cross sectional area of air ableto enter the vaporiser body.

We will now walk through the electrical functionality of oneimplementation. Note that some simplification may be used in theconsumer product; what we will describe below is the prototypeimplementation, which has been optimised for testing.

The steps or logic is as follows:

1) The device starts in standby mode and is therefore inactive

2) The user activates the PV 1 by pressing a microswitch 70, protrudingfrom a slot in the outer case 100.

3) A solenoid 22 mounted on the Receptacle Chassis 2 is powered frombattery 68, itself also mounted on Receptacle Chassis 2.

4) Solenoid 22 locks 4 Way Sliding Contact Block 5 against the PV RingConnector 49.

5) Power to solenoid 22 is limited to 10 seconds unless the ReceptacleChassis 2 is rotated 15°.

6) Receptacle Chassis 2 is rotated 15° against resistance of leaf spring17 (the user squeezes the bottom of the Chassis into the Case 100).

7) Microswitch 70 activates closing contacts at termination of 15°travel.

8) Upon Microswitch activation, power is sent from Battery 68 to thecoil and wick assembly 52 in the PV 1, via 4 Way Sliding Connector 5 andthe PV Ring Connector 49.

9) The PV coil 52 temperature is monitored by on board electronics(directly or indirectly as a function of power delivered and time).

10) The power supply to the coil 52 is terminated when the coil 52reaches its operational temperature, or a defied time has elapsedsufficient for the coil to reach operational temperature; generally thisis achieved in under 1s or 2s.

11) The power supply to Solenoid 22 is then terminated, unlocking 4 WaySliding Connector 5.

12) 4 Way Sliding Connector 5 then retracts 2 mm under spring 23 force,breaking both electrical connection between PV PCB 60 and the EPV MainChassis PCB 16 and also terminating the mechanical interlock between thePV 1 and 4 Way Sliding Contact Block 5.

13) The PV 1 then springs upwards and clear of the Receptacle Chassis 2,ready for removal.

14) The PV 1 is then removed from Receptacle Chassis 2 by the user andplaced between lips.

15) The user inhales on the mouthpiece of PV 1.

16) Air Pressure Sensor 58 in the air stream inside PV 1 senses airmovement and sends power to vaporiser Coil 52.

17) The PV 1 on-board Battery 59 supplies power to vaporiser Coil 52.

18) The PV 1 vaporiser Coil 52 temperature is monitored by on-boardelectronics whilst there is air flow.

19) The PV 1 vaporiser Coil 52 temperature is controlled by cutting &re-instating power from on-board battery 59.

20) After cessation of vaping, the PV 1 is placed back in the Case 100,i.e. Receptacle Chassis 2.

21) The Receptacle Chassis 2 returns to its Standby Mode Position, 0°,under Spring 17 power.

22) A camming action of the Receptacle Chassis 2 closing against OuterCase 6 & 7 imparts linear travel to EPV.

23) Linear travel causes pump 4 to transfer vaping liquid to replenishthe PV 1 on-board reservoir.

24) PV 1 is returned to standby mode—inactive in the case.

One further feature is that the vaping experience is a function of anumber of variables, such as e-liquid constituents, power delivered tothe atomiser, temperature reached, airflow etc. It is possible for thecase to store different profiles, such as ‘light’, ‘smooth’, ‘intense’,‘maximum vapour quantity’, ‘maximum strength’, ‘warmer vapour’, ‘coolervapour’ etc. Each of these could also be a function of a specific brandof e-liquid. The user can then select on their smartphone app thespecific profile and/or variables that meet their preferences.

Also, the specific brands of e-liquid could themselves determinespecific variables of the case and PV. Hence a user could select ontheir smartphone app to use say a ‘Marlboro’ brand of e-liquid, and thenthe case would automatically configure parameters such as power,temperature etc to give the ideal experience for that specific brand.The parameters could be stored in software or firmware in the case orthe PV. It would also be possible to obtain an application from an appstore, such as the Apple App Store, or Google Play, specific to a brandof e-liquid; this app would then automatically configure the connectedcase with the appropriate parameters for optimum performance for thatbrand of e-liquid.

In the preceding part of Section A, we detailed the operation of thefollowing features:

Feature 1: Combined re-charge and re-fill storage and carrying case

Feature 2: Case with movable PV holder

Feature 3: Re-Filling the PV

Feature 4: PV Locking mechanism

In the following part of Section A, we will look at:

Feature 5. Data connectivity

Feature 6. E-fulfilment

Features 5 & 6. Case with Data Connectivity and E-Fulfilment

In this section, we describe in more detail the features of dataconnectivity and e-fulfillment, first introduced at the start of SectionA.

To re-cap on the data connectivity feature: this is a portable, personalstorage and carrying case for an e-liquid e-cigarette PV in which thecase includes a data processor that controls sending a signal requestinga replacement for a user-replaceable e-liquid cartridge in the case.

The related e-fulfilment method is a method used in portable, personalstorage and carrying case adapted specifically for a refillablee-cigarette PV and that re-fills and re-charges the PV, the methodincluding the steps of the case (a) transferring e-liquid from auser-replaceable e-liquid cartridge to the PV and (b) automaticallysending a signal requesting a replacement for the user-replaceablee-liquid cartridge to an e-fulfilment platform, either directly or via aconnected smartphone.

The method may include the steps of the case (a) detecting the level ofor quantity of e-liquid in a user-replaceable e-liquid cartridge in thecase and (b) automatically sending a signal requesting a replacement forthe user-replaceable e-liquid cartridge to an e-fulfilment platform,either directly or via a connected smartphone. Note that ‘detecting thelevel of or quantity of e-liquid in a user-replaceable e-liquidcartridge in the case’ could be direct, or could be indirect, such asinferred from the number of re-fills of the PV that have been completedwith that cartridge, or the total number of inhalations made with thatcartridge, or any other way of intelligently determining whether areplacement cartridge should be ordered. Machine learning can also bedeployed to analyse the user's usage patterns; for example, if the usertends to vape heavily over the weekend but quite lightly during theweek, then that can be taken into account when determining when areplacement cartridge should be ordered. Likewise, a degree of directinteraction between e-liquid vendors and end-users is possible; when auser is likely to be ordering replacement cartridge(s), then specialoffers, or offers for new flavours or new strengths of e-liquid can besent (e.g. text, instant message etc) to the user, or any other way ofcementing brand loyalty.

Enabling the case to send a request for a replacement e-liquid cartridgeis very convenient for the user and also ensures that replacementcartridges are supplied in a timely manner—this is especially importantwhen the user is on a tobacco or nicotine reduction programme since ifthe case runs out of e-liquid, then the user may well be tempted back tousing cigarettes. So the efficacy of adopting this system as a cigarettereplacement (and health concerns with cigarettes is overwhelmingly thereason given for e-cigarette adoption) benefits greatly from the timely,automatic, background ordering of replacement cartridges.

Optional features (each of which can be combined with others) includethe following:

-   -   the data is substance-consumption related data    -   the cartridge(s) are in normal use replaceable by a user but are        not refillable by a user.    -   the processor is programmed to send data over a wire or via a        wireless data connectivity interface.    -   the processor is programmed to send and/or receive data from the        personal vapourising device.    -   the processor, or an associated processor, is programmed to        determine and store when the case is opened and/or shut.    -   the processor, or an associated processor, is programmed to        measure or record the charge level of a battery in the portable        re-filling unit and also the charge level in a battery in the        personal vapouriser.    -   the processor, or an associated processor, is programmed to        detect cartridge type and volume.    -   the portable re-filling unit is adapted to receive substance        consumption-related data from the personal vapouriser.    -   the processor, or an associated processor, is programmed to        measure consumption of the or each substance, including related        factors, such as time, location, temperature.    -   the processor, or an associated processor, is programmed to        output consumption-related data, organized according to any one        or more of the following variables: part of the day/night,        daily, weekly, seasonal, weather, any other factor.    -   the processor, or an associated processor, is programmed to        control any one or more of: mixing of e-liquids from different        cartridges in the re-filling unit; nicotine or smoking cessation        or reduction, period between ‘vapes’; re-ordering e-liquid;        age/parental controls, social network updates; e-liquid        recommendations.    -   the processor, or an associated processor, is programmed to use        the consumption-related data for the or each substance in an        algorithm that calculates when to place an order for one or more        replacement cartridges or prompt a user that one or more        replacement cartridges should be ordered.    -   The processor, or an associated processor, is programmed to        order replacement cartridges when running low, either by        directly sending a request to a fulfillment server, or sending a        message to a connected smartphone or wearable device, for the        smartphone or wearable device to send a request to a fulfillment        server.    -   the processor, or an associated processor, is programmed to        control mixing and consumption of the or each substance.    -   the processor, or an associated processor, is programmed to use        location data, such as location data from a GPS or other        satellite or land-based location-finding system.    -   the location data is from a location finding system in the        portable re-filling unit itself or the personal vapouriser.    -   the processor, or an associated processor, is programmed to        provide an alert to the user, directly or via a smartphone or        wearable device, if close to a retail store where consumables        for the personal vapouriser are obtainable.    -   the processor is programmed to send and/or receive data with a        tablet, smartphone, wearable device or any other secondary        computing device, or with a personal vapouriser.    -   the tablet, smartphone, wearable device, PC, laptop or other        secondary computing device is programmed (e.g. with a        downloadable app) to perform any of the functions listed        above—i.e. the existing computational power and 3G/4G wireless        connectivity and GPS capability of the tablet/smartphone etc. is        used instead of having to build that capability into the        re-filling unit.    -   the processor, or an associated processor, is programmed to        provide data to and/or receive data from a downloadable        smartphone application.    -   the downloadable smartphone application can control the portable        re-filling unit.    -   the downloadable smartphone application can control any one or        more of: mixing of e-liquids from different cartridges in the        re-filling unit; nicotine or smoking cessation or reduction,        period between ‘vapes’; re-ordering e-liquid; age/parental        controls, social network updates; e-liquid recommendations;        parameters that determine PV performance or the vaping        experience (e.g. power, temperature, airflow).    -   the processor is programmed to integrate with a personal        assistant program such as Google Now, Apple Siri, etc.    -   the portable re-filling unit can be remotely locked and unlocked        from the smartphone application, such as by entering a PIN.    -   the portable re-filling unit can be remotely locked and unlocked        from the smartphone application or other remote device, to        prevent release of the vapourising device from the re-filling        unit, as an aid to cessation or reduction of substance usage, to        prevent tampering, to prevent access by children.    -   the portable re-filling unit can be remotely locked and unlocked        automatically depending on whether a smartphone paired with the        unit is within a specified range or is able to exchange        appropriate data with the unit.    -   the data is sent over a wireless link, or a direct electrical        connection

The following section describes these features with reference to theFigures; the relevant Figures are FIGS. 55 and 57.

FIG. 55 is a high-level schematic showing a portable re-filling caseable to communicate wirelessly and also through a wired connection to asmartphone, a laptop and a modem; these devices send data via theinternet or other network—this can be any of the consumption data(including how consumption varies according to the various parameters,such as part of the day/night, daily, weekly, seasonal, weather, time,location, temperature and any other factor). This data is especiallyvaluable to PV vendors, especially if it can be associated with ademographic profile of the device user; that demographic profile can beentered by the user when they register their device online (e.g. onfirst purchase of the PV, or when they wish to buy e-liquids, or set upautomatic e-fulfillment of replacement e-liquid), or can be extracted orinferred from social network posted information. The data can also beused by an e-fulfillment company to process the order and to providereplacement consumables (e-liquid, PV, case) to the user.

FIG. 57 shows schematically that the portable re-filling unit includeselectronics componentry, such as a memory, wireless/wired connectivity,software, and a controller/processor. Also, the cartridge includes fourcompartments, each with a different flavor or strength of e-liquid; thecase is able to monitor the consumption of e-liquid in each compartmentand share that consumption data with the connected smartphone app, aswell as the e-fulfillment platform.

The re-filling unit itself can measure how much e-liquid is left in itscartridge(s) or tank(s). There are various ways of doing so:

1. Ultrasonic ranger for depth, some a tilt sensor to detect the angleof the cartridge and whether the e-liquid closes an electrical circuitbetween different electrical contacts at different levels within thecartridge.

2. Measure the weight of the tank(s)

3. Capacitive sensor. As the e-liquid has a different permittivity withrespect to air, if concentric circles of conductors are kept in avertical position, a height change in e-liquid will result in aproportional change in capacitance between the conductors. This can befed to a circuit which can detect the change and thereby a change ine-liquid level.

4. Using an air pressure sensor at the top of a flexible tube whosebottom is held just above the bottom of the tank. The pressure in thetube changes as the e-liquid level goes up and down. This would be verysafe, inexpensive, rugged and reliable.

Each of these techniques can also be used in the PV itself.

Section B. PV: Simplicity and Ease of Use

Preceding Section A focused on aspects of the re-filling and re-chargingcase. We will now move on, in this new Section B, to describing variousfeatures in the e-cigarette PV itself. The PV implements a number ofuseful features that contribute to the user experience, defined bysimplicity and ease of use.

Following on from the consecutive numbering used in Section A, thesefeatures are:

Feature 7. Re-fillable and re-chargeable PV

Feature 8. PV with pre-heat

Feature 9. PV with dosage indication

Feature 10. PV with drip prevention

We will look at each of these in turn.

Feature 7. Re-Fillable and Re-Chargeable PV

A significant problem with conventional e-cigarette PV designs is thatre-filling a cartridge reservoir is slow and can be messy; it typicallyrequires the user to purchase small bottles of e-liquid and to carefullydis-assemble the PV and then re-fill the cartridge by lining up thenozzle of a bottle and squeezing gently. Equally, removing a spent,non-refillable cartridge and replacing it with a new cartridge, whilstnot messy, is wasteful, especially as typical cartridges are notrecyclable.

The feature is a re-fillable and re-chargeable e-cigarette PV that isnot disassembled in normal use for re-filling or replenishing withe-liquid and is also not disassembled in normal use for battery accessor replacement or other battery interaction.

A second aspect of this feature is a re-Tillable and re-chargeablee-cigarette PV with a casing that includes a rechargeable battery, are-Tillable e-liquid reservoir and an atomiser, none of which areremovable from, or separable from, any part of the casing in normal use.The body of the casing may be a one-piece, unitary casing (typicallycircular or square in profile), with components introduced from eitheror both ends.

A third aspect of this feature is a re-Tillable and re-chargeablee-cigarette PV designed in normal use to only be re-fillable withe-liquid and re-chargeable when inserted into or otherwise engaged witha carrying case for the PV, the carrying case being specifically adaptedto re-fill and re-charge the PV.

Ensuring that the PV does not need to be dis-assembled in normal use,for charging or re-filling e-liquid, leads to a much simpler userexperience. Furthermore, it enables the design to be much more robust,since there need be just a single, strong unitary casing with no screwthreads allowing dis-assembly; robustness is very important for aconsumer device that will be returned to and withdrawn from its casethousands of times, dropped and generally not treated gently.

A fourth aspect of this feature is a re-fillable and re-chargeablee-cigarette PV with a tip that includes (a) an e-liquid filling aperturethat is designed to engage an e-liquid transfer mechanism (b) one ormore vapour outlets distributed around the e-liquid filling aperture;and electrical charging contacts spaced apart from the tip.

The relevant Figures are FIGS. 7-11. FIG. 7 shows the PV case 100 whichserves also as a e-liquid re-filling unit; it includes a replaceablee-liquid cartridge 3 and a battery 68 that can re-charge the battery inthe PV 1. FIG. 7 is a cross-section view of the re-filling unit 100 andthe PV 1; FIG. 8 shows the PV 1 being inserted into the re-filling unit100; FIG. 9 shows the pump action dispenser in the re-filling unit 100automatically replenishing the e-liquid reservoir in the PV 1 whilst thePV 1 is being pushed down; FIG. 10 shows the PV 1, fully replenished,and stored in case 100 (when the PV 1 is stored in the case, PV 1 isalso pushed down to activate the pump dispenser to ensure the PV 1 isfully replenished with e-liquid).

PV 1 is not dis-assembled in normal use for re-filling the reservoir orotherwise replenishing or replacing the substance. The battery 5 in there-filling unit 1 also charges the battery in the PV 1 whilst PV 1 isstored in the re-filling unit 1.

The detailed design of the working prototype, shown in FIGS. 19 and 20and fully described in Section A above, also exemplifies the abovefeatures.

Feature 8. PV with Pre-Heat

Conventional e-cigarettes often only start heating the atomiser once aninhalation is detected; as a result, the first inhalation can give quitea poor experience and it is only after two or three inhalations that theatomiser has sufficiently heated the e-liquid that a good vapingexperience is provided.

In this section, we describe a number of different ‘pre-heat’ features.With these ‘pre-heat’ feature, because the PV can start heatingautomatically, there is no need for an ‘on’ switch in the PV,contributing to the simplicity of the user experience, and also reducingcost.

The first pre-heat feature is a portable, personal storage and carryingcase for an e-liquid e-cigarette PV that starts providing power to heatan electrical atomising element in a PV automatically when the case inwhich the PV is stored is opened. By using the battery in the case toprovide the power for this pre-heating, this saves depleting the batteryin the PV.

The second ‘pre-heat’ feature is an e-cigarette PV that automaticallyheats an electrical atomising element when the PV detects that it is nolonger in electrical contact with the charging contacts in a portablecarry case in which it is stored (e.g. when the case is opened and thePV pops up out of the case).

The first and second pre-heat features can be combined—e.g. the firstphase is for the battery in the case to provide power for pre-heatingwhen the case is opened; the second phase is for the battery in the PVto take-over heating when it detects that the PV is no longer in contactwith the electrical power contacts in the case and hence can no longerrely on power from the case. Normally, this second phase occurs onlyonce the pressure sensor in the PV detects that the user is inhaling.

A third pre-heat feature is a portable, personal storage and carryingcase for an e-liquid e-cigarette PV which includes a locking system tolock the PV securely in a heating position during which time the PV isheating using power from a power source in the case and, after the PVhas been sufficiently heated, to release the locking mechanism. The caseautomatically may move the PV to a position which allows it to bereadily removed from the case by an end-user once the PV has beensufficiently heated. The user can also press the PV back down when it isin the case to initiate heating.

In this section, we also introduce the feature of the PV automaticallyindicating when it has reached the correct operating temperature: Apersonal vapourising device storing a substance to be vapourised, thedevice including a means of indicating by visual cue, audible cue, touchfeedback, haptic, vibration, heat or other sensory signal, or prompt,when the device has sufficiently heated the substance to a predeterminedtemperature or for a predetermined time, so that the device is ready foruse. Hence, the PV (or indeed the case) may show when the PV is readyfor use because heating to an operational level has been reached orheating for a predefined time has occurred. For example, a simple LEDmay glow when the PV is ready for inhalation.

This kind of indicator is very useful because if the user tries toinhale before the atomizer is effectively able to create a vapour withthe correct characteristics (which happens if the e-liquid is too cooland viscous), then the user experience is very poor.

Optional features of the PV (each of which can be combined with others)include the following:

-   -   heating of the e-liquid begins when a case, such as a portable        re-filling case, storing the device is opened to show the        device.    -   heating of the e-liquid can be done by secondary heating        elements in the PV e-liquid chamber; these heating elements are        not meant to heat the e-liquid to vapourising temperature, but        to simply raise the e-liquids temperature so that the e-liquid        transported by the wick to the heating elements that do heat to        vapourising temperature is already pre-heated.    -   heating of the substance to the temperature at which the device        is ready for use can be predicted or inferred with sufficient        accuracy because the charge level of the battery used to provide        power to heat the substance is known reliably.    -   the charge level is known reliably because a sensor directly        measures that charge level.    -   the charge level is known reliably because it can be assumed to        be fully charged because the device is stored in a case that        includes a battery that automatically charges the battery in the        device.    -   heating of the substance begins automatically when the device is        removed from its case.    -   heating of the substance begins when the device is slotted into        or otherwise engaged with the case so as to securely engage, for        extraction from the case, a new capsule including the substance        to be vapourised.    -   the indicator is a visual indication, or a sonic indicator, or a        tactile indicator or a vibration indicator.

The following section describes these features with reference to theFigures; the relevant Figure is FIG. 58. Referring to FIG. 58:

A: As the vapouriser leaves the case electrical contact is broken withthe case and the vapouriser automatically starts to heat the liquid(pre-heating)

B: Shows how the charge contacts between case and PV are broken as thePV is removed from the case

C: A light on the PV flashes or glows when the PV is ready to use, asshown schematically by the small circle with radial lines. The ‘ready’indication could instead or in addition be a vibration or sound as well.

Pre-heating can also start when the case is simply opened and before thePV is withdrawn (the user may set (e.g. via a smartphone app) whetherpre-heating starts at merely opening the case, or only when the PV iswithdrawn from the case). Starting the heating process whilst the PV isstill fully in the case enables the battery in the case to be used toprovide power (typically by topping up the charge in the PV's internalbattery as that internal battery provides the current to the atomizer).The detailed design of the working prototype, and fully described inSection A above (in particular FIGS. 25 and 26 and the relateddescription), also exemplifies the above features.

This document also describes (Feature 13) a single capsule dispenser, inwhich the PV uses a small capsule with e-liquid and that capsule isextracted from a dispenser by the user inserting the PV into thedispenser; a single capsule is then engaged onto the end of the PV. Inthis variant, pre-heating of the e-liquid begins when the device isengaged into a case so as to securely engage a capsule including thesubstance to be vapourised; the PV includes the same kind of indicatorto show that the PV is ready for use (e.g. the correct operatingtemperature has been reached); an alternative is that the PV pops out ofthe case when it is ready for use.

In each case, the temperature is not typically measured directly(although it may be); instead, that can be inferred from the currentdrain, resistance of the atomizer heating element, and any otherrelevant factor(s). Using the elapsed time of heating can be a simpleand effective proxy for e-liquid temperature with this system,especially as the local battery in the PV will generally be fullycharged or close to fully charged when heating starts, since it iscontinuously charged whilst the PV is stored in the case. Also, becausethe PV itself and the case can have knowledge of when the PV was lastused and for how long, the remaining charge in the PV battery can bereliably inferred and the predicted time of heating can be automaticallyaltered to compensate for varying levels of charge. In conventional PVswith a small rechargeable battery, time can generally not be used as aproxy because users do not reliably keep the battery close to fullycharged.

Feature 9. PV with Dosage Indication

In this section, we describe the feature of an e-cigarette PV thatindicates consumption of e-liquid using a visual indicator that extendsor moves down the body of the PV away from the mouthpiece. The visualindicator moves or extends fully to indicate that a single dose has beenconsumed.

Optional features of the PV (each of which can be combined with others)include the following:

-   -   the indication is visual, audible, touch feedback, haptic,        vibration, heat or any other sensory signal.    -   the indicator can be a visual indicator that extends or moves        down towards the end of the device distant from the mouthpiece,        and in which extending or moving from a start position to a        final position corresponds to consuming or vapourising a single        dose of the substance.    -   the indicator can also include a visual indicator that extends        or moves around the device, and in which extending or moving        from a start position to a final position corresponds to        consuming or vapourising a single dose of the substance.    -   the indicator can provide a visual indication that alters to a        specific colour when a single dose of the substance has been        consumer or vapourised.    -   the indicator can provide a haptic indication.    -   the indicator can provide a heat-based indication.    -   there is an additional indicator showing the charge level of a        battery in the device.    -   the or each indicator is implemented in a module that a user can        connect in-between a conventional battery and any of: a        conventional cartridge, atomizer or cartomiser.    -   the module can screw into the conventional battery and the        conventional cartridge, atomizer or cartomiser.    -   the PV also can include a humidity sensor capable of monitoring        humidity changes and is capable of evaluating how much vapour        the device is producing.        -   the humidity sensor is positioned at the mouth of a            cartomisor.        -   the humidity sensor is implemented in a module that a user            can connect in-between a conventional battery and any of the            following: conventional cartridge, atomizer or cartomiser.        -   the humidity sensor is implemented in a battery pack            component, or a cartomiser, or an atomizer, or a mouthpiece.        -   the PV configured to use humidity data for dosage control.        -   the PV is configured to transmit humidity data to a case, a            connected smartphone or directly to a computing device.    -   the PV can be designed to engage with a portable re-filling        storage and carrying case that includes a reservoir for the        e-liquid from which the personal vapouriser can be refilled, and        in which the vapouriser can only, in normal use, be refilled        when slotted into or otherwise engaged with the portable case        and that case is operable to re-fill the personal vapouriser so        that the personal vapouriser has a single dose of the substance        to be vapourised.    -   the PV can be designed to engage with a portable unit for        storing the portable vapourising device, in which the unit is        programmed to prevent release of the device for predetermined        amounts of time as an aid to cessation or reduction of substance        usage.        -   time is indicated through colour lights or a countdown            timer.

This feature also encompasses a personal vapourising device including ahumidity sensor capable of monitoring humidity changes and thereforecapable of evaluating how much vapour the device is producing.

Optional features of the PV (each of which can be combined with others)include the following:

-   -   the humidity sensor is implemented in a module that a user can        connect in-between a conventional battery and any of the        following: a conventional cartridge, atomizer or cartomiser.    -   the humidity sensor is implemented in a battery pack component,        or a cartomiser, or an atomizer, or a mouthpiece.    -   the PV is configured to use humidity data for dosage control.    -   the PV is configured to transmit humidity data to a case, a        connected smartphone or directly to a computing device.

This feature also encompasses a portable unit for storing a portablevapourising device, in which the unit is programmed to prevent releaseof a personal vapouriser device for predetermined amounts of time as anaid to cessation or reduction of substance usage. Time may be indicatedthrough coloured lights or a countdown timer on the portable unit, orvia data transmitted to a secondary device that could display thisinformation.

The following section describes these features with reference to theFigures; the relevant Figures are FIG. 2, and FIGS. 59-60.

An example of vapouriser including an indication of how much substancehas been vapourised is shown in FIG. 59, in which the quantity of vapourinhaled is inferred using a pressure sensor that senses when a userinhales (and optionally the strength of the inhalation or the volumeinhaled), plus a time sensor that measure for how long an inhalationlasts.

There are various ways to indicate when a single or end-user set dose ofthe e-liquid has been consumed or vapourised.

A: A light moves down the vapouriser as if it is ‘burning down’. Asimilar visual indicator is shown in FIG. 2; a series of twelve LEDsprogressively light up as the PV consumes nicotine equivalent to asingle cigarette—typically one LED lights up per inhalation, where thee-liquid strength used means that twelve inhalations corresponds tosmoking a single cigarette. The user can also set the LEDs so that asingle LED lights up when nicotine equivalent to an entire cigarette isconsumed. Hence, the FIG. 2 device would show when the equivalent ofbetween one and twelve entire cigarettes had been consumed.

B: Single light changes colour to show how much has been inhaled. Atraffic light system (green, amber, red) or change in brightness oflight (dimming with usage) could be used and when the light shows red oris fully dimmed out it means that the dose has been provided; the PV mayat this time stop working for a set period if the user is on a nicotineor smoking cessation or reduction programme.

C: the light, at one end of, or anywhere on the PV, changes colour, asabove.

A conventional PV can be adapted to use this feature: FIG. 60 shows aconventional two part PV, with an e-liquid cartridge above the atomizerand the atomiser above the battery, but by adding a third module betweenthe standard cartridge/atomizer/cartomiser and the battery where theadditional new module includes an indicator that alters to indicate whena single or end-user set dose of the substance has been consumed orvapourised, as described above. Many conventional PVs use standardsizes, so this approach enables a conventional PV to be upgraded to onethat is far more useful in a smoking or nicotine cessation or reductionprogram.

FIG. 61 is another approach to dosage control: the PV case is programmedto prevent release of the PV for predetermined amounts of time as an aidto cessation or reduction of substance usage, tamper prevention,preventing children accessing the PV etc. The case itself may indicatethat a single dose, including an end-user set dose, of the substance hasbeen consumed or vapourised in the PV it is storing. The case can beprogrammed or controlled (e.g. from the user's smartphone) not to powerup for a specified period of time, at certain times, or at a certainfrequency or duration; these could all be variable and adjusted by thesmartphone app.

FIG. 62 shows the humidity sensor variants as described above.

Feature 10. PV Drip Prevention

In this section, we describe several drip-prevention features in the PV.

The first feature is a PV includes a tip that includes (a) an e-liquidfilling aperture that is designed to engage an e-liquid transfermechanism, the aperture being centrally positioned along the long axisof the PV, the aperture being connected to an e-liquid storage chamberin the PV; (b) one or more vapour outlets distributed around thee-liquid filling aperture; and in which the vapour outlets are connectedby passages to a vapour chamber including a vaporising element, and thevapour chamber is sealed from the e-liquid storage chamber.

The second feature is a PV with e-liquid leak suppression where ane-liquid filling aperture in the PV is adapted to align, when insertedinto a re-filling unit, with a hollow tube that is part of a fluidtransfer system in the re-filling unit, and the aperture includes aflexible seal through which the tube is inserted or passes, the sealensuring that any drips of e-liquid are retained within the PV when thePV is withdrawn from or removed from the re-filling unit.

The third feature is a PV with e-liquid leak suppression where thevapour passage is not a straight through path from the atomiser butinstead includes at least one turn and terminates in one or more vapouroutlets distributed around an e-liquid ingestion nozzle positionedcentrally along the long axis of the PV.

Optional features of the PV (each of which can be combined with others)include the following:

-   -   the presence of the barriers causes the length of the passage to        be substantially longer than if there were no barriers.    -   the barriers ensure that the passage is not a straight path.    -   the barriers cause the width of the passage to be constricted        compared to the width the passage would have if there were no        barriers.    -   the barriers comprise a double cap.    -   the barriers make the passage a serpentine path.    -   the passage is lined with an absorbent material to absorb any        droplets that escape from the unit, without impeding the flow of        vapour through the passage.

These features also encompass a personal vapouriser comprising a unitstoring a substance to be vapourised, an atomizer and a passageconnecting the atomizer to a mouthpiece through which vapour may bedrawn by a user, wherein the passage is lined with an absorbent materialto absorb any droplets that escape from the unit, without impeding theflow of vapour through the passage.

The detailed design of the working prototype, fully described in SectionA above, also exemplifies the above first and second features.

The following section further describes these features with reference tothe Figures; the relevant Figures are FIGS. 63-37.

FIG. 63A shows a second barrier in the mouthpiece that does notsignificantly impede vapour flow but provides a harder, tortuous path(the dark arrow) for e-liquid droplets to follow. A solid tube aroundthe e-liquid store has been added to stop droplets of e-liquid beingsqueezed out (conventional PVs may have a flexible tube that can besqueezed). a Soft flexible skin around the solid tube can be providedfor better tactility.

FIG. 63B shows a variant in which the vapour path is not tortuous as inFIG. 63A, but instead a double cap is provided in the mouthpiece, makingit much less likely that e-liquid droplets will escape.

FIG. 63C shows a further variant in which a series of fins in themouthpiece makes it much less likely that e-liquid droplets will escape.

FIG. 64 shows a seal being placed over the end of the e-liquid saturatedcloth; by capping the saturated cloth in this way with a consistent andeffective seal, it makes it much harder for e-liquid droplets to migrateinto the inhalation track. In FIG. 64, this is combined with anelongated cap, again reducing the possibility that any droplets ofe-liquid will leak out.

FIG. 65 shows adding a seal to the end of the e-liquid saturated cloth,but also adding a dry cloth or foam insert to absorb any droplets thatdo escape, and to prevent vapour build up. If any small droplets doadhere to the side of the internal cap, then the return shape of theinternal cap leads them away from the inhalation tip.

The choice of absorbent material is important:

Hydrophilic absorbent material that absorbs water and water basedliquids is effective. The material is in a compact tube form to fit intothe small space in an inhalator end, and it swells by absorbing rapidlya liquid such as water or liquidised nicotine based gel.

Types of Material Include but are not Limited to:

-   -   Synthetic sponge    -   Synthetic Chamois    -   Microfiber synthetic cloth    -   Hydrogel (Hydrogels are highly absorbent (they can contain over        90% water) natural or synthetic polymeric networks)

Absorption materials should not absorb moisture in vapour suspension asthis would harm inhalation, only liquids that are free moving in thevapouriser case are absorbed. The hydrophilic material could also bechanged periodically to ensure the vapouriser performance is notreduced.

FIG. 66 shows the approach of moving the e-liquid reservoir to the endfurthest from the mouthpiece—this provides a much longer path for anye-liquid droplets to flow before reaching the mouthpiece. It alsobalances the cigarette more naturally and provides a bettervaping/vapour experience.

FIG. 67 shows containing the e-liquid in a sealed container to stopdroplet migration. The wick will leave the container via a tight holeand use capillary action to retain a wet coating. It is highly unlikelythat the wick will itself permit the migration of droplets of e-liquidthat could then leak out from the mouthpiece.

Section C: User-Replaceable E-Liquid Cartridge

Whereas Section A focused on the storing and carry case, and Section Bfocused on the PV, in this Section C we describe the features of theuser-replaceable e-liquid cartridge.

Following the consecutive numbering in earlier sections:

Feature 11. User-Replaceable E-Liquid Cartridge

A first feature is a user-replaceable e-liquid cartridge adapted to beinserted into or attached to portable, personal storage and carryingcase for an e-liquid e-cigarette PV. FIG. 5 shows the cartridge 3 andthe Section A description of the working prototype that uses thiscartridge. FIG. 6 shows a different design of cartridge 3 withdrawn fromcase 100. FIG. 7 shows cartridge 3 fully inserted into case 100.

A complimentary feature a portable, personal storage and carrying casefor an e-liquid e-cigarette PV in which the case includes auser-removable e-liquid cartridge.

Key Subsidiary Features:

-   -   e-liquid cartridge has a casing that is adapted to be fitted by        a user into a chamber in a portable, personal storage and        carrying case for an e-liquid e-cigarette PV.    -   cartridge has an outer surface that forms part of the casing of        the case (with this variant, the cartridge is still ‘in the        case’, and the case still ‘includes the cartridge’ as those        phrases are used in this specification)    -   cartridge attaches to the case—e.g. the cartridge forms an        extension to the case; with case and cartridge when combined        forming a unitary object (with this variant, the cartridge is        still ‘in the case’, and the case still ‘includes the cartridge’        as those phrases are used in this specification)    -   e-liquid cartridge is not substantially deformable in normal use        in order to displace fluid from the cartridge    -   e-liquid cartridge is made using PET    -   e-liquid cartridge is designed to slot inside a portable,        personal storage and carrying case for an e-liquid e-cigarette        PV with a press fit against a seal and in which the cartridge is        formed with a void designed to receive and engage with a        micro-pump that is positioned in the case, the micro-pump        sealing against a nozzle in the cartridge.    -   e-liquid cartridge is designed to slot inside a portable,        personal storage and carrying case for an e-liquid e-cigarette        PV with a press fit against a seal and in which the cartridge        includes an integral micro-pump    -   case includes a user-replaceable cartridge with several        compartments and can fill the PV by combining e-liquid from        several compartments    -   case includes several user-removable e-liquid cartridges and can        fill the PV by combining e-liquid from several cartridges    -   case and/or cartridge includes an overflow channel that enables        excess e-liquid that is pumped up from the cartridge but is not        stored in the PV to be captured and returned to the cartridge    -   cartridge screws into the case    -   cartridge includes electronic identifier, such as RFID chip.    -   Cartridge includes physical features on its surface, such as        raised or lowered portions, that physically engage with        complimentary features in the wall of the case aperture into        which the cartridge is inserted.    -   The physical features form the shape of a word or logo, such as        a trademarked word or logo

In this section, we describe in more detail the feature of there-filling unit including multiple user-replaceable cartridges/chambers:A portable unit for re-filling a reservoir in a portable vapourisingdevice, the unit including multiple user-replaceable cartridges orchambers, each containing a substance to be vapourised, in which theunit enables the portable vapourising device to be filled with onespecific substance, or a predetermined mixture of two or moresubstances.

Optional features (each of which can be combined with others) includethe following:

-   -   a user may specify which substance is used to refill the PV.    -   a user may specify refilling the substance(s) to create a custom        mixture.    -   a customised mixture may be in accordance with a smoking or        nicotine cessation or reduction program.

Combining the multi cartridge/chamber approach with the features of theFeature 5 ‘Intelligent case’ leads to many useful and novel features:for example, the case can learn which flavours/strengths of e-liquid theuser prefers, possibly as a function of time of day, location, day ofthe week, time of the day. Like a good personal assistant, the case canthen prepare in advance the right flavour/strength given these factorsor even suggest that it does so to the user (e.g. a message could appearon the user's smartphone app that exchanges data with the PV and/orcase). The case and/or related smartphone app (or any other kind ofconnected electronic device, such as wearable glasses, a smartwatch etc)also recommend new flavour(s) or other things that the user may like, inmuch the same way as an online music service.

The following section describes these features with reference to theFigures; the relevant Figures are FIGS. 56 and 57.

An example of a portable charging and re-filling case equipped with fourseparate cartridges (numbered 1, 2, 3 and 4) is shown in FIG. 56A. Fourcartridges have been used for illustrative purposes, but this could bemore or less.

FIG. 56B shows the four cartridges loaded into a carriage; eachcartridge will typically have a different strength or type of e-liquid.For example, if the user following a smoking or nicotine cessation orreduction program, each cartridge could have a different strength ofnicotine; one cartridge could be a placebo or a vitamin/mineral e-liquidor just the standard propylene glycol base. Another approach could be tohave e-liquids of similar nicotine strength, but with differentflavours. It would also be possible to have different flavours oftotally nicotine-free e-liquid—this might be especially useful tosomeone who has successfully completed a nicotine cessation program.Each cartridge is individually user replaceable (but not in normal userefillable, although this is one possible variant).

The carriage has small valves (not shown) used to permit or prevente-liquid flowing from each cartridge through to the refilling mechanism,under the control of the software and processor in the unit (which mayin turn be under the control of the user's smartphone or otherdevice—typically, the user would enter the desired mix into an apprunning on a smartphone, and the smartphone would then send theappropriate control data to the processor in the unit; the smartphonecan be replaced by any other suitable type of computing device,including wearable computing devices receiving touch based and/or spokencommands). The unit may also include a touch screen that enables theuser to enter the desired mix directly into the unit. Mixing of thee-liquids can occur in the carriage itself, or in a separate chamber onleaving the cartridge.

FIG. 56C shows a single cartridge with four chambers; the cartridgeincludes the valves (each shown schematically as circle with a line)that enable different chambers to be opened or closed as appropriateunder the control of the software and the processor (again, usually,implementing instruction received from the user's smartphone). Mixing ofthe e-liquids can occur in the cartridge itself, or in a separatechamber on leaving the cartridge. The whole cartridge is userreplaceable (but not in normal use refillable, although this is onepossible variant).

FIG. 57 shows how the user's smartphone can display the current levelsof e-liquid in each cartridge:

In Step A, the electronics in the case record the level of thecartridges.

In Step B, when the vapouriser is inserted into the case it transfersits usage data to the electronics in the case.

In Step C, the case gives a visual indication when at least onecartridge level is low. This can take into account current levels in thecartridge(s), and also predicted future levels taking into account therate of consumption by the user and how much e-liquid is left in the PVitself.

In Step D, the case sends data to a connected smartphone device toinform of the low cartridge level. The case may take into account howmuch e-liquid is left in or has been consumed by the vapouriser, and therate at which it has been consumed in the past, when determining whetherto alert the user or order replacement cartridges.

The smartphone can display a message such as ‘Order replacementCartridge 2, which is nicotine strength xx?’, or “We predict that youwill run out of e-liquid nicotine strength xx at your currentconsumption rate in 4 days, shall we re-order?’ together with a ‘BuyNow’ option. If the user selects the ‘Buy Now’ option, then a message issent over the internet to an e-fulfillment provider, who then sends outthe replacement cartridge to the user, who then installs it into thecase.

The above ‘Multi-liquid’ cartridge can be controlled by anelectro-mechanical valve system that regulates the volume of liquidflowing through the valve, whereby moving a pin controls the flow andquantity of liquid into an anti-chamber, in turn creating a definedmixture which is then injected into the vapouriser by either anon-pressurised or pressurised pump system. This could be electronicallycontrolled to mix a predefined volume and mixture of liquids. Examplesbeing

-   -   Predefined smoking cessation program to reduce down the nicotine        levels over a period of time.    -   To mix several liquids to make unique flavours.    -   Move from Menthol inhaling to straight nicotine based inhaling        liquid.    -   Cartridge Lock-out for child protection

Miscellaneous Features Feature 12. Hygienic PV

In this section, we introduce the feature of the PV including a hygienicmouthpiece: A personal vapourising device including a housing and amouthpiece, in which the mouthpiece is extendable from and retractablewithin a body of the device.

Optional features of the PV (each of which can be combined with others)include the following:

-   -   the mouthpiece is made of a soft touch material.    -   the mouthpiece is extended from the housing when the tip of the        device at the end opposite to the mouthpiece is depressed by the        user.    -   extending the mouthpiece causes the device to automatically        start heating the substance to be vapourised.    -   a second depression by the user causes the mouthpiece to retract        within the body of the device.

The following section describes these features with reference to theFigures; the relevant Figures are FIGS. 68 and 69.

FIG. 68 shows a PV with an outer sleeve through which themouthpiece/atomizer and battery parts of the PV can slide. FIG. 68Ashows a schematic external view, with the mouthpiece or inhalation tipfully extended; FIG. 68B is a cross sectional view of FIG. 68A, showingthe mouthpiece/atomizer and battery parts. In FIG. 68C, the inhalationtip is fully retracted within the sleeve; as a consequence, the batteryend of the PV is now protruding out of the sleeve. FIG. 68D shows theinternal parts of the FIG. 68C view. When the inhalation tip is fullyretracted, the user can click on the other end to cause the inhalationtip to pop out; clicking it again can cause the tip to retract, in muchthe same was a clicking the top of a ballpoint pen. Clicking the end tocause the inhalation tip to pop out can also be used to turn the PV onto start heating.

FIG. 69 shows the same four views, but this time with a different designof PV (described more fully as Feature 14). In this different design, asingle dose capsule is secured at the end of the PV furthest from theinhalation tip; pushing the soft-tip inhalation into the sleeve/housingcauses the capsule to be ejected.

Feature 13. Single Capsule Dispenser

In this section, we introduce the feature of a dispenser storingmultiple capsules, each containing a substance to be vapourised, whereinthe dispenser enables a personal vapourising device to be inserted intothe dispenser to securely engage a capsule.

Optional features of the capsule dispenser (each of which can becombined with others) include the following:

-   -   a stack of capsules is inserted into the dispenser and a spring        urges the stack up inside the dispenser.    -   the spring may be any other type of device for applying a force.    -   a capsule is designed to securely engage with the vapourising        device when the device is pressed against the capsule.    -   a single capsule includes substance equivalent to a single        [combustible] cigarette.    -   a single capsule includes an amount of substance designed for a        nicotine or smoking cessation or reduction program.    -   a single capsule can be any of the following: nicotine,        caffeine, vitamin, mineral, flavoured substance, or any mixture        of any of these.    -   different capsules can be selected by the user to be different        strengths of nicotine.    -   different capsules can be selected by the user to be different        flavours of nicotine.    -   different capsules can be selected by the user to be different        types of vapourisable substance.

The following section describes these features with reference to theFigures; the relevant Figure is FIG. 70.

FIG. 70A: A stack of capsules is inserted into the dispenser and aspring (or any other type of device for applying a force) urges thestack up inside the dispenser.

FIG. 70B and 70C: A capsule is designed to securely engage (e.g. a pressfit) with the PV device when the PV device is inserted down into thecase and pressed against the capsule. The capsule engages with the endfurthest from the inhalation tip/mouthpiece.

The PV can be withdrawn from the case, with the capsule securelyattached. A single capsule typically includes e-liquid equivalent to asingle cigarette. A single capsule may also include an amount ofsubstance designed for a cigarette or nicotine cessation or reductionprogram—hence the stack of capsules shown in FIG. 70A may haveprogressively less nicotine.

Feature 14. Single Capsule PV

In this section, we introduce the feature of a PV with an ejectablesingle-dose capsule: A personal vapouriser device including a capsulecontaining substance to be vapourised at one end of a housing furthestfrom the mouthpiece and where the capsule is ejected by the userpressing a component in the device.

Optional features of the PV (each of which can be combined with others)include the following:

-   -   the component pressed by the user is a button.    -   the component pressed by the user is a mouthpiece and in which        the mouthpiece is slid out from and retracted back into the        housing, the mouthpiece retracting causing the capsule to eject.    -   a single capsule includes an amount of substance equivalent to a        single cigarette.    -   a single capsule includes an amount of substance of a        predetermined amount as decided or selected by the user.    -   a single capsule includes an amount of substance designed for a        cigarette or nicotine cessation program.    -   the PV is designed to engage with a dispenser storing multiple        capsules, each containing a substance to be vapourised, wherein        the vapourising device is inserted in normal use into the        dispenser to securely engage a capsule.

This feature encompasses also a personal vapouriser comprising a unitstoring a substance to be vapourised, and a mouthpiece at one end, inwhich the reservoir storing the substance to be vapourised is placedtowards the end furthest from the mouthpiece.

Optional features of the PV (each of which can be combined with others)include the following:

-   -   the unit is a capsule that encapsulates the substance.    -   the unit is a conventional e-cigarette cartridge.    -   unit is pressed on to the end of the vapouriser and securely        engages with the vapouriser.

The following section describes these features with reference to theFigures; the relevant Figures are FIGS. 66 and 69.

FIG. 66 shows moving the e-liquid chamber to the end furthest from themouthpiece; in this case, the entire cartomiser is moved to the endfurthest from the mouthpiece. This balances the PV more naturally and soprovides a better experience.

FIG. 69 shows a single dose capsule is secured at the end of the PVfurthest from the inhalation tip; pushing the soft-tip inhalation intothe sleeve/housing causes the capsule to be ejected.

Feature 15. Various Constructional Improvements

This section describes a broad range of constructional improvements; therelevant Figures are FIGS. 71 to 76.

FIG. 71 shows an e-liquid capsule (typically with a single dose ofnicotine, e.g. equivalent to a single cigarette, or a pack of 5cigarettes). The capsule is inserted by the user into the heatingatomizer and then places the mouthpiece over the capsule; a piercingpoint forms a small puncture in the top of the capsule, enabling heatedvapour to be drawn through the mouthpiece. This design allows user toknow how much they are ‘vaping’ and is also a much cheaper and easier touse refill approach, compared with conventional approaches.

FIG. 72 shows a spiraled, acid etched element being used as the heatingelement; the acid etching increases the effective surface area of theheating element; rolling the element up in a spiral around a saturatedmat allows a much larger element than is normal, again giving faster andmore efficient vapour production and also inhibits the saturated matfrom releasing droplets of e-liquid.

FIG. 73 shows wrapping an acid etched heating element around the outsideof an e-liquid saturated core; this approach provides a large heatingarea, but is simpler than the spiral arrangement of FIG. 111. A secondbarrier prevents droplet leakage.

FIG. 74 shows a large wick, made of compressed fibres like a markerpen's nib, inserted into and drawing e-liquid from a container; thesides of the wick that are external to the e-liquid container are incontact with an acid-etched heating element; the effectiveness of thewick in drawing up e-liquid provide a consistent vapour.

FIG. 75 shows using a pair of piezo transducers that generate ultrasonicwaves to produce the e-liquid vapour; the e-liquid is in a sealedchamber with a water tight valve that can release vapour but notdroplets.

FIG. 76 shows using a chemical heat source to heat the e-liquid; acombination of chemicals are encapsulated together with an e-liquidcontainer; when the capsule is pushed against a piercing pin at one endof a sleeve, mixing of the chemicals generates enough heat to create avapour, which the user sucks through the mouthpiece. Enough heat couldbe provided to vapourise a single dose. This design eliminates the needfor batteries or control electronics. It would be cheap to manufacture.

1. A portable, personal storage and carrying case for an e-liquide-cigarette PV in which the case includes: (a) a refillable PV that isremovable from the case; (b) an electrical power source for re-charginga rechargeable battery in the PV; (c) a user-replaceable reservoir forholding e-liquid; and (d) an electrical or electronic pump adapted totransfer e-liquid from the reservoir to a chamber in the PV, the pumpdelivering a pre-defined or variable quantity of e-liquid from thereservoir; and in which the case is configured to automatically fullyre-fill the PV with e-liquid and fully charge the PV so that the PV isin a fully re-filled and re-charged state when it is removed from thecase.
 2. The case of claim 1, in which the case completely encloses thePV when the case is closed.
 3. The case of claim 1, in which the case isconfigured to re-fill the PV with e-liquid when the PV is inserted intothe case, without the need to dis-assemble or puncture the PV,maintaining the PV whole and intact.
 4. The case of claim 1, in whichthe case displays a visual indication of e-liquid volume remaining inthe reservoir.
 5. The case of claim 1, in which the case includes ahinged compartment for receiving and holding the PV.
 6. The case ofclaim 1, in which the case has closed and open positions, and exposesthe top of the removable PV when in the open position to enable a userto readily withdraw the PV from the case.
 7. The case of claim 1, inwhich the case is configured to lift the PV up to facilitate withdrawalof the PV from the case.
 8. The case of claim 1, in which the case islockable to prevent use by unauthorized persons, including under-agepersons.
 9. The case of claim 1, in which the case is lockable remotelyfrom a smartphone app.
 10. The case of claim 1, in which a smartphoneapp implements a nicotine reduction or cessation program and controlsoperation of the case.
 11. The case of claim 1 in which the caseautomatically locks the PV into a secured re-charging and re-fillingposition when the case is fully closed for storage and carrying the PV.12. The case of claim 1 which includes a locking system to lock the PVsecurely in a heating position during which time the PV is heating usingpower from a power source in the case and, after the PV has beensufficiently heated, to release the locking system.
 13. The case ofclaim 1, in which the refillable PV is approximately the same size as acigarette and it includes no ‘on’ button.
 14. The case of claim 1 inwhich the refillable PV is configured when filled to enable vapingequivalent to just 1 cigarette.
 15. The case of claim 1, in which therefillable PV ceases to work once e-liquid equivalent to a singlecigarette has been consumed, but will resume after re-filling in thecase.
 16. The case of claim 1, in which the PV includes indicators thatshow when e-liquid equivalent to a single cigarette is present in thePV.
 17. The case of claim 1, in which the PV includes indicators thatshow when e-liquid equivalent to a single cigarette has been consumed.18. The case of claim 1 in which the pump is a peristaltic pump.
 19. Thecase of claim 1, in which the reservoir is not user-refillable.
 20. Thecase of claim 1, in which the reservoir includes a unique identifierchip.
 21. The case of claim 1 in which the user-replaceable e-liquidreservoir fits in the case or is otherwise attached to the case.
 22. Thecase of claim 1 in which the user-replaceable e-liquid reservoir isdesigned in normal use to permit e-liquid to escape only if thereservoir is correctly positioned in the case.
 23. The case of claim 1in which the e-liquid capacity of the user replaceable reservoir is atleast three times greater than the e-liquid capacity of the chamber inthe PV.
 24. The case of claim 1 in which the case includes an overflowchannel or return path that enables excess e-liquid that is pumped upfrom the reservoir but is not stored in the PV to be captured andreturned to the reservoir.
 25. The case of claim 1 in which the case orthe user-replaceable reservoir detects the level of e-liquid or thequantity of e-liquid in the user-replaceable reservoir.
 26. The case ofclaim 1 which includes a data processor that controls sending a signalrequesting a replacement for the user-replaceable e-liquid reservoir inthe case.
 27. The case of claim 1 which includes a data processor thatcontrols sending a signal reminding the user that a replacement isneeded for the user-replaceable e-liquid reservoir in the case.
 28. Auser-replaceable e-liquid reservoir for dispensing e-liquid, insertedinto, or otherwise attached to, a portable, personal storage andcarrying case for an e-liquid e-cigarette PV and engaging with anelectrical or electronic pump fluid transfer system in the case, thecase including: (a) a refillable PV that is removable from the case; (b)an electrical power source for re-charging a rechargeable battery in thePV; and (c) the electrical or electronic pump, being configured totransfer e-liquid from the e-liquid reservoir to a chamber in the PV,the pump delivering a pre-defined or variable quantity of e-liquid fromthe reservoir; and in which the case is configured to automaticallyfully re-fill the PV with e-liquid and fully charge the PV so that thePV is in a fully re-filled and re-charged state when it is removed fromthe case.
 29. A method of operating a portable, personal e-cigarettesystem, the method including the steps of: (a) inserting a refillable PVinto a storage and carrying case for the PV; (b) inserting or attachinga user-replaceable reservoir for holding e-liquid to the case; (c)recharging the PV with an electrical power source in the case; (d)operating an electrical or electronic pump in the case to transfere-liquid from the reservoir to a chamber in the PV, the pump deliveringa pre-defined or variable quantity of e-liquid from the reservoir; andin which the case is configured to automatically fully re-fill the PVwith e-liquid and fully charge the PV so that the PV is in a fullyre-filled and re-charged state when it is removed from the case.